Molding Apparatus

ABSTRACT

This manufacturing method of a molded surface fastener involves a primary molding step for forming a primary molded body and a secondary molding step for compressing a provisional element of the primary molded body while heating the same. A molding apparatus is provided with a mold member comprising multiple penetration holes and multiple concave portions, whereof each penetration hole communicates to at least one concave portion; in the primary molding step, the molding apparatus is used to form a primary molded body comprising a provisional element having a primary stem portion and a pawl portion is formed from the protruded portion by compressing the provisional element. By this means, it is possible to stably manufacture a molded surface fastener that has an engaging element comprising a pawl portion that projects from the outer peripheral edge of an engaging head portion.

This application is a divisional of U.S. patent application Ser. No.16/062,038, which is incorporated by reference herein in its entirety.

TECHNICAL FIELD

The present invention relates to a manufacturing method of a moldedsurface fastener in which a plurality of male engaging elements stand onan upper surface of a flat plate-shaped base portion and a moldingapparatus used for manufacturing the molded surface fastener.

BACKGROUND ART

Surface fastener products in which a pair of a female surface fastenerhaving a plurality of loops and a male surface fastener which can beattached to and detached from the female surface fastener are combinedand used are conventionally known. A male surface fastener manufacturedby molding synthetic resin is generally formed such that a plurality ofmale engaging elements having a mushroom shape and the like stand on anupper surface of a flat plate-shaped base portion.

Surface fastener products having such a male surface fastener are usedin a wide variety of goods nowadays, and they are often used for goodsto wear such as disposable diapers, diaper covers for babies, supportersto protect limb joints, lumber corsets (belt for backache) and gloves.

Many kinds of molded surface fasteners used for disposable diapers havebeen developed, including JP2013-529974 A (Patent Document 1) forexample.

The molded surface fastener described in Patent Document 1 is formed bystanding a plurality of male engaging elements on a flat plate-shapedbase portion. Each engaging element has a truncated stem portion and anengaging head portion integrally formed on the stem portion. Theengaging head portion is formed to bulge from the stem portion in thesame volume in all directions.

In at least some of the engaging elements of Patent Document 1, thebulging part of the engaging head portion extending in only onedirection of x-direction or y-direction is directed downward to the baseportion. According to Patent Document 1, the molded surface fastenerhaving the engaging elements as mentioned above can have high peelingstrength at the time of engaging with the surface fastener havingloop-shaped female engaging elements.

Meanwhile, U.S. Patent Publication No. 2013/0067702 A specification(Patent Document 2) discloses a molded surface fastener in whichengaging and separating properties are enhanced. Engaging elementsprovided on the molded surface fastener in Patent Document 2 has a stemportion standing on the base portion and an engaging head portionintegrally formed on the stem portion. On an outer peripheral edge partof the engaging head portion, a plurality of teeth are provided to berotation symmetry about a center point.

In Patent Document 2, as a method for manufacturing a molded surfacefastener, a method of extruding molten synthetic resin material betweena molding roller and a pressure roller is used. In this case, aplurality of molding cavities having a shape corresponding to theengaging elements of the molded surface fastener are formed on the outerperipheral surface of the molding roller.

Since the synthetic resin material is extruded between the moldingroller and the pressure roller as above, a base portion is molded at agap between the molding roller and the pressure roller, and engagingelements are integrally molded with the base portion by pushing thesynthetic resin material into the molding cavities of the molding rollerby the press roller. Then, after the synthetic resin material is curedwhile being rotated together with the molding roller, the curedsynthetic resin is taken out from the molding cavities of the moldingroller and peeled off from the molding roller, thereby the moldedsurface fastener of Patent Document 2 is manufactured.

WO 2000/000053 Publication (Patent Document 3, JP2002-519078 Publicationcorresponds thereto) discloses a method for manufacturing a surfacefastener having a plurality of male engaging elements and amanufacturing apparatus therefor.

For example, in the manufacturing method described in Patent Document 3,a primary molding step for molding a primary molded body 80 having aflat plate-shaped base portion, a stem portion standing on the baseportion and a primary head portion integrally formed on the stem portionis conducted, as shown in FIG. 42. Then, a secondary molding step formolding an engaging head portion by flattening the primary head portionin a diameter direction by passing the primary molded body 80 through acalender and pressing the primary head portion of the primary moldedbody 80.

In this case, the molding apparatus 81 for conducting the above primarymolding has a molding cylindrical body 82 which rotates, a presscylinder 83 disposed facing to the molding cylinder 82 at apredetermined interval and an extruding head 84 which supplies moltenthermoplastic resin between the molding cylinder 82 and the presscylinder 83. The molding cylinder body 82 of Patent Document 3 has anouter side screen 85 having a cylindrical shape and an inner side screen86 having a cylindrical shape and contacting with an inner peripheralsurface of the outer side screen 85 as shown in FIGS. 43 and 44.

On the outer side screen 85 of the molding cylinder 82, a plurality ofcavities 87 which has a columnar shape and molding the stem portions. Onthe inner side screen 86, a plurality of cavities which has a columnarshape and molding the primary head portions. Each cavity 87 of the outerside screen 85 and each cavity 88 of the inner side screen 86 aredisposed to be aligned at positions corresponding to each other.

Using the above molding apparatus 81 having such a molding cylinder 82,the molding cylinder 82 and the press cylinder 83 are rotated, and athermoplastic resin material is supplied from the extruding head 84between the molding cylinder 82 and the press cylinder 83. As a result,the primary molded body 80 in which a plurality of engaging elementshaving the stem portion and the primary head portion and having dents onthe primary head portions stand on the base portion is molded.

Then, the obtained primary molded body 80 is passed through the calenderto make each primary head portion thin, thereby the molded surfacefastener according to Patent Document 3 in which a plurality ofmushroom-shaped engaging elements stand on the base portion ismanufactured. Further, the molded surface fastener manufactured inPatent Document 3 has a characteristics that a concave portion is formedat a center part of the upper surface of the engaging head portion ofeach engaging element.

PRIOR ART DOCUMENT Patent Documents

Patent Document 1: JP 2013/529974 A

Patent Document 2: US 2013-0067702 A

Patent Document 3: WO2000/000053 A

SUMMARY OF INVENTION Problems to be Solved by the Invention

Generally, for molded surface fasteners used for goods to be put on abody such as a disposable diaper or a diaper cover, it is demanded thatattaching and detaching a male surface fastener and a female surfacefastener is easy to be done, and an engaging strength (peeling strength)is enhanced so that a male surface fastener and a female surfacefastener do not separate easily even in a case of moving one's body whenboth are engaged. Further, the molded surface fastener may be directlycontacted with one's skin depending on the goods. Therefore, improving atexture on a top surface side of the molded surface fastener on whichthe male engaging elements are disposed has also been demanded in orderto obtain soft touch feeling. Therefore, the molded surface fastenerdescribed in Patent Document 3 has room for further improvement in orderto solve the above problems.

Accordingly, the specific objective of the present invention is toprovide a manufacturing method of a molded surface fastener capable ofmanufacturing a molded surface fastener having a large engaging strength(peeling strength) with respect to a female surface fastener and fromwhich excellent texture can be obtained stably, and a molding apparatusused for manufacturing the molded surface fastener.

Means for Solving the Problems

In order to achieve the above object, a method for manufacturing amolded surface fastener provided by the present invention is, as a mostprincipal structure, a method for manufacturing a molded surfacefastener made of synthetic resin in which a plurality of engagingelements stand on an upper surface of a flat plate-shaped base portion,and each engaging element has a stem portion standing on the baseportion and an engaging head portion integrally formed on the stemportion, the method includes a primary molding step for molding aprimary molded body having the base portion and a plurality ofprovisional elements standing on the base portion, and a secondarymolding step for molding the molded surface fastener by heating theprovisional elements of the primary molded body and compressing theprovisional elements from above, in which the method includes, in theprimary molding step, continuously molding the primary molded body inwhich at least a part of the provisional elements has a primary stemportion standing on the base portion and at least one protruded portionprotruded from an outer peripheral side surface on an upper end part ofthe primary stem portion using a molding apparatus having a mold memberprovided with a plurality of penetration holes drilled to penetrate froman outer peripheral surface to an inner peripheral surface and aplurality of concave portions concaved on the inner peripheral surfaceand in which each penetration hole communicates to at least one of theconcave portions, and a driving part rotating the mold member at apredetermined speed, and the method includes, in the secondary moldingstep, molding the stem portion and the engaging head portion as well asmolding at least one pawl portion protruded on the outer peripheral edgepart of the engaging head portion from the protruded portion bycompressing an upper end part of the provisional elements from above.

The manufacturing method of the present invention preferably includesmolding a rib portion bulging upward from the upper surface of theprimary stem portion and an additional protruded portion protruded fromthe rib portion to an outside of the primary stem portion to theprovisional element using the molding apparatus further having anauxiliary mold member disposed closely contacting with the innerperipheral surface of the mold member on an inside of the mold memberand in which auxiliary concave portions communicating to the penetrationholes of the mold member are concaved on an outer peripheral surface,and molding the pawl portion from the protruded portion and theadditional protruded portion in the secondary molding step.

Another method for manufacturing a molded surface fastener according tothe present invention is, as a most principal structure, a method formanufacturing molded surface fastener made of synthetic resin on which aplurality of engaging elements stand on an upper surface of a flatplate-shaped base portion, in which the method includes molding themolded surface fastener in which the engaging element has a stem portionstanding on the base portion and at least one pawl portion protrudedfrom the outer peripheral side surface on an upper end part of the stemportion using a molding apparatus having a mold member which has aplurality of penetration holes drilled to penetrate from the outerperipheral surface to the inner peripheral surface and a plurality ofconcave portions concaved on the inner peripheral surface and in whicheach penetration hole communicates with at least one of the concaveportions and a driving part rotating the mold member at a predeterminedspeed.

In this case, it is preferable that the manufacturing method of thepresent invention includes deforming the pawl portion of at least a partof the engaging elements so as to protrude from the outer peripheralside surface of the stem portion parallel to the upper surface of thebase portion or toward the base portion.

It is also preferable that the method includes molding a rib portionbulging upward from the upper surface of the stem portion and anadditional pawl portion protruded to an outside of the stem portion fromthe rib portion to the engaging element using the molding apparatusfurther having an auxiliary mold member disposed closely contacting withthe inner peripheral surface of the mold member on an inside of the moldmember and in which auxiliary concave portions communicating to thepenetration holes of the mold member are concaved on an outer peripheralsurface.

Further, it is preferable that in the above manufacturing method of thepresent invention, a member having a cylindrical shape is used as themold member.

Next, a molding apparatus provided by the present invention is a moldingapparatus used for manufacturing a molded surface fastener made ofsynthetic resin on which a plurality of engaging elements stand on anupper surface of a base portion, the molding apparatus having, as abasic structure, a molding member, a driving part rotating the moldmember at a predetermined speed and an extrusion nozzle extruding moltensynthetic resin material toward the mold member, in which the moldmember is provided with a plurality of penetration holes drilled topenetrate from an outer peripheral surface to an inner peripheralsurface and a plurality of concave portions concaved on the innerperipheral surface, and each penetration hole of the mold membercommunicates with at least one of the concave portions.

In the molding apparatus of the present invention as above, it ispreferable that the mold member has a cylindrical shape, and a die wheelis formed using the mold member and the driving part.

It is preferable that the molding apparatus of the present invention hasan auxiliary mold member disposed closely contacting with the innerperipheral surface of the mold member on an inside of the mold memberand in which auxiliary concave portions communicating to the penetrationholes of the mold member are concaved on an outer peripheral surface,and the auxiliary mold member is rotated synchronously with the moldmember.

Further, in the molding apparatus of the present invention, the concaveportion is preferably a linear concave groove portion and a concavegroove portion curved in a wavy shape.

In this case, it is preferable that a groove width of each concavegroove portion is set at 0.005 mm or more and 0.1 mm or less, and agroove depth of each concave groove portion is set at 0.005 mm or moreand 0.05 mm or less.

Effects of the Invention

In the method for manufacturing a molded surface fastener according tothe first embodiment of the present invention, firstly, a primary moldedbody having a base portion and a plurality of provisional elementsstanding on the base portion is molded using a molding apparatus in aprimary molding step.

The molding apparatus used at this time has a mold member and a drivingpart rotating the mold member at a predetermined speed. The mold memberhas a plurality of penetration holes drilled to penetrate from an outerperipheral surface to an inner peripheral surface and a plurality ofconcave portions concaved on the inner peripheral surface and allowingmolten synthetic resin (molten resin) to flow in. Further, the moldmember is formed such that each penetration hole communicates to atleast one concave portion, and is capable of flowing molten resinfilling the penetration hole from the outer peripheral surface side inthe concave portion provided on the inner peripheral surface from thepenetration hole.

The primary molding step is conducted using such a molding apparatus,thereby the primary molded body in which at least a part of theprovisional elements has a primary stem portion standing on the baseportion and at least one protruded portion protruded from the outerperipheral side surface in an upper end part of the primary stem portionis continuously molded.

Subsequently, a secondary molding step is conducted to heat theprovisional elements of the primary molded body and to compress theprovisional elements from the above. In the secondary molding step, astem portion standing on the base portion and an engaging head portionintegrally formed on the stem portion are molded from the primary stemportion and the protruded portion of the provisional element, and at thesame time, at least one pawl portion protruded on an outer peripheraledge part of the engaging head portion is molded from the protrudedportion of the provisional element. Thereby, a molded surface fastenerhaving the engaging elements on which at least one micro pawl portion isprotruded on the outer peripheral edge part of the engaging head portioncan be manufactured efficiently and stably.

In the molded surface fastener thus manufactured, the pawl portionprotruded on the outer peripheral edge part of the engaging head portioncan have a pawl width dimension smaller than a width dimension of aboundary between the stem portion and the engaging head portion. Thepawl width dimension here means a dimension of the pawl portion in adirection perpendicular to a protruding direction of the pawl portion ora bulging direction of the engaging head portion as well as a directionperpendicular to an upper and lower direction (standing direction of thestem portion) of the molded surface fastener.

The width dimension in the boundary means a dimension of imaginarystraight line passing through a center of the boundary surface betweenthe stem portion and the engaging head portion in one arbitrarydirection among directions (or flat surfaces) perpendicular to an upperand lower direction (standing direction of the stem portion) of themolded surface fastener. In the present invention particularly, it meansa dimension of a machine direction (MD: direction in which the moldedsurface fastener is conveyed) among the directions perpendicular to thestanding direction of the stem portion in a molding step of the moldedsurface fastener. Further, in the engaging elements of the presentinvention, in a case that the boundary surface is a circular shape in aplan view, for example, a width dimension of the boundary is the same asa size of a diameter of a circular cross section of the boundarysurface.

In the molded surface fastener manufactured by the present invention,the micro pawl portions are protruded on the outer peripheral edge partof the engaging head portion as mentioned above. Particularly, byconducting the above second molding step, the pawl portion can be formedto slope or curve downward toward the base portion from the engaginghead portion. Therefore, an engaging strength with respect to loops isenhanced.

Although it is not limited to the case, when loops (engaging elements)of a female surface fastener are engaged with engaging elements of themolded surface fastener of the present invention, the loops of thefemale surface fastener can be hooked easily with the pawl portions ofthe engaging elements. As a result, the loops of the female surfacefastener can be less dropped off from the engaging elements of thepresent invention (less removed), and the engaging strength isincreased.

Therefore, according to the molded surface fastener manufactured by thepresent invention, the engaging strength (peeling strength) with respectto a female surface fastener can be effectively enhanced. Thus, in acase that the manufactured molded surface fastener is used for goodssuch as a disposable diaper, for example, even when various moves areconducted in a state that the molded surface fastener and a femalesurface fastener are combined, its combined state can be stablymaintained.

Further, in the molded surface fastener manufactured by the presentinvention, the pawl portion provided on the outer peripheral edge partof the engaging head portion is minute. Therefore, when touching themolded surface fastener from the upper surface side which is theengaging surface, an influence on texture of the molded surface fastenerby the pawl portion is reduced, and smooth touch feeling or soft andflexible touch feeling can be easily obtained. That is, according to themanufacturing method of the present invention, a male molded surfacefastener having a high engaging strength and excellent texture of asurface can be stably provided.

In the manufacturing method according to the first embodiment of thepresent invention as above, a molding apparatus having the abovementioned mold member, an auxiliary mold member disposed closelycontacting with the inner peripheral surface of the mold member on aninside of the mold member and in which auxiliary concave portionscommunicating to the penetration holes of the mold member are concavedon an outer peripheral surface, and a driving part rotating the moldmember and the auxiliary mold member at a predetermined speed can beused in the primary molding step. Thereby, the primary molded body inwhich at least a part of the provisional elements has the primary stemportion and the protruded portion as mentioned above, a rib portionbulging upward from the upper surface of the primary stem portion and anadditional protruded portion protruded from the rib portion to anoutside of the primary stem portion can be molded continuously.

Subsequently, the second molding step heating the provisional engagingelements and compressing the provisional elements from the above isconducted to the obtained primary molded body. Thereby, the stem portionand the engaging head portion are molded, and at the same time, a pawlportion can be molded from the protruded portion and the additionalprotruded portion of the provisional element to an outer peripheral edgepart of the engaging head portion. Thereby a plurality of pawl portionscan be stably provided on the engaging head portion. Thus, the moldedsurface fastener having higher engaging strength can be stably provided.

Since the molding apparatus used for the primary molding step has themold member forming the protruded portion on the provisional element andthe auxiliary mold member forming the additional protruded portion onthe provisional element, the pawl portion and the additional pawlportion can be provided as different protruded portions. Further, forexample, the protruded portion and the additional protruded portion ofthe provisional element can be formed in different sizes from eachother. Therefore, in the present invention, a molded surface fastenerhaving an engaging element in which pawl portions having different sizesare protruded on one engaging head portion can also be manufactured.

In the manufacturing method of the molded surface fastener according tothe second embodiment of the present invention, a molded surfacefastener having a base portion and a plurality of engaging elementsstanding on the base portion is molded using a molding apparatus. Themolding apparatus used therefor has a mold member and a driving partrotating the mold member at a predetermined speed. The mold member isprovided with a plurality of penetration holes drilled to penetrate fromthe outer peripheral surface to the inner peripheral surface and aplurality of concave portions concaved on the inner peripheral surfaceand allowing molten synthetic resin (molten resin) to flow in. Further,the mold member is formed such that each penetration hole communicateswith at least one concave portion, and molten resin filling thepenetration hole from the outer peripheral surface side can be flowedinto the concave portion provided on the inner peripheral surface fromthe penetration hole.

As the molding step is conducted using such a molding apparatus, amolded surface fastener in which at least a part of the engagingelements has a stem portion standing on the base portion and at leastone pawl portion protruding from the outer peripheral side surface onthe upper end part of the stem portion can be molded continuously andmanufactured efficiently and stably.

In the molded surface fastener thus manufactured, the pawl portionprotruded on the outer peripheral side surface of the stem portion canhave the pawl width dimension smaller than a length of a line segmentpassing through the center on the upper surface of the stem portion andconnecting two points on the upper end outer peripheral edge of the stemportion. Here, the line segment to be compared with the pawl widthdimension of the pawl portion means an imaginary straight line passingthe upper surface center of the stem portion and connecting two pointson the upper end outer peripheral edge of the stem portion in the planview of the engaging element. The imaginary straight line isperpendicular to the upper and lower direction (standing direction ofthe stem portion) of the molded surface fastener.

It is preferable that the line segment of the imaginary straight line asabove is a line segment along a machine direction (MD: direction inwhich the molded surface fastener is conveyed) in the molding step ofthe molded surface fastener among directions perpendicular to thestanding direction of the stem portion. Further in the presentinvention, in a case of the upper surface of the stem portion of theengaging element show a circular shape parallel to the upper surface ofthe base portion, a diameter of the circular upper surface of the stemportion corresponds to the line segment of the imaginary straight line.

In the molded surface fastener manufactured by the present invention,the micro pawl portions are protruded on the outer peripheral sidesurface of the upper end part of the stem portion, as mentioned above.The engaging element formed of such a stem portion and the micro pawlportions has a new shape different from conventional and generally knownones in a J-shape, a palm-tree shape or a mushroom shape.

In such an engaging element, the stem portion is easy to secure a largestrength. Therefore, a shear strength of the manufactured molded surfacefastener with respect to a female surface fastener can be effectivelyincreased. Further, the stem portion has a large strength while theengaging element has no engaging head portion. Therefore, the engagingelement of the manufactured molded surface fastener can be smoothlyinserted between loops of the female surface fastener. In addition, theengaging element can be pushed deeply close to a root of the loops withrespect to the female surface fastener. Thereby, the pawl portion of theengaging element can be hooked firmly to the loops and stably engaged.

Furthermore, in the molded surface fastener manufactured as above, theflat upper surface of the stem portion is exposed upward broadly, theengaging head portion is not provided, and only the micro pawl portionsare formed to bulge to an outside from the stem portion. Therefore, whentouching the molded surface fastener on the upper surface side which isto be an engaging surface, smooth touch feeling and soft and flexibletouch feeling can be easy to be obtained. That is, according to themanufacturing method of the present invention, the characteristic malemolded surface fastener in which the stem portion of the engagingelement is hard to be bent, the pawl portion can hook a loop firmly toengage, and texture on the surface is excellent can be stably provided.The characteristic molded surface fasteners of the present invention areprovided in addition to conventional molded surface fasteners, therebythe molded surface fasteners have a wide variety. As a result, they caneasily correspond to various kinds of female surface fasteners (nonwovenfabric) more precisely.

In the manufacturing method according to the second embodiment of thepresent invention, after the molded surface fastener having the engagingelements are molded with the mold member of the molding apparatus, themolded surface fastener is held and pulled by an upper and lower pair ofpickup rollers, thereby the molded surface fastener can be peeled offfrom the mold member. At this time, the engaging elements are pressedfrom above with the rotating pair of pickup rollers (upper side holdingroller, particularly). Therefore, it is possible that the pawl portionformed on at least a part of the engaging elements is deformed toprotrude parallel to the upper surface of the base portion or sloped orcurved downward to the base portion from the outer peripheral sidesurface of the stem portion. Further, the pawl portion of the engagingelement can be deformed to slope or curve downward further by conveyingthe molded surface fastener while heating, and blowing a hot air fromabove of the engaging elements after the molded surface fastener ispeeled off from the mold member with the pickup rollers.

That is, in the manufacturing method according to the second embodiment,the pawl portion molded with the molding apparatus is formed by beingpulled out forcibly from the mold member of the molding apparatus.Therefore, in some cases, it is protruded to extend upward above theupper surface of the stem portion from the outer peripheral side surfaceof the stem portion. On the other hand, the pawl portion of the engagingelement can be deformed intentionally by pressing it with the pickuprollers from above as mentioned above, thereby the pawl portion can beprotruded from the outer peripheral side surface of the stem portion tobe parallel to the upper surface of the base portion or slope or curvedownward to the base portion.

As the pawl portion is formed in such a protruding direction, when theloops of the female surface fastener are engaged with the molded surfacefastener, the loops can be stably engaged with the pawl portions of theengaging elements, and the loops hooked by the pawl portions can be hardto be pulled out from the engaging elements. Therefore, the engagingstrength (peeling strength) of the molded surface fastener with respectto the female surface fastener can be further increased.

Further, in the manufacturing method according to the second embodimentof the present invention, and in the molding step of the molded surfacefastener, the molding apparatus having the mold member as above, theauxiliary mold member closely contacting with the inner peripheralsurface of the mold member on an inside of the mold member and in whichauxiliary concave portions communicating to the penetration holes of themold member are concaved on an outer peripheral surface, and the drivingpart rotating the mold member and the auxiliary mold member at apredetermined speed. Thereby, the molded surface fastener in which atleast a part of the engaging elements has the above-mentioned stemportion and pawl portion, a rib portion bulging upward from the uppersurface of the stem portion and an additional pawl portion protrudedfrom the rib portion toward an outside of the stem portion can be moldedcontinuously.

Thereby, the pawl portion and the additional pawl portion can beprovided to the engaging element as different protruded portions.Therefore, the molded surface fastener having higher engaging strengthcan be stably provided. Since the molding apparatus having the moldmember and the auxiliary mold member is used, the pawl portion and theadditional pawl portion in different sizes from each other can be easilyformed on the engaging element, for example.

Further in the present invention, a member (die wheel) having acylindrical shape can be used as a mold member of the molding apparatusin the manufacturing method according to the first and secondembodiments as mentioned above. Thereby, the molding apparatus can beformed in a simple structure, and the primary molded body in the firstembodiment or the molded surface fastener in the second embodiment canbe stably molded using the molding apparatus.

Next, a molding apparatus of the present invention used formanufacturing a molded surface fastener has a mold member, a drivingpart rotating the mold member at a predetermined speed and an extrusionnozzle extruding molten synthetic resin material toward the mold member.The mold member has a plurality of penetration holes drilled topenetrate from the outer peripheral surface to the inner peripheralsurface and a plurality of concave portions concaved on the innerperipheral surface. Further, each penetration hole of the mold membercommunicates with at least one concave portion.

The molding apparatus of the present invention as above can be formed ina simple structure. It can also mold the primary molded body in thefirst embodiment and the molded surface fastener in the secondembodiment stably and efficiently as in the above. Particularly, themicro protruded portions provided on the primary molded body in thefirst embodiment and the micro pawl portions provided on the moldedsurface fastener in the second embodiment can be stably molded.

In the molding apparatus of the present invention, the mold member has acylindrical shape, and a die wheel is formed using the mold member andthe driving part. By using such a molding apparatus, the primary moldedbody in the first embodiment or the molded surface fastener in thesecond embodiment can be stably molded.

The molding apparatus of the present invention also has an auxiliarymold member disposed closely contacting with the inner peripheralsurface of the mold member on an inside of the mold member and in whichauxiliary concave portions communicating to the penetration holes of themold member are concaved on an outer peripheral surface. Further, theauxiliary mold member rotates synchronously with the mold member. Usingsuch a molding apparatus, the additional protruded portion as mentionedabove can be stably formed on the provisional engaging element of theprimary molded body in the first embodiment, and the additional pawlportion as mentioned above can be stably formed on the engaging elementof the molded surface fastener in the second embodiment.

Further, in the molding apparatus of the present invention, concavegroove portions in a linear shape or concave groove portions curved in awavy shape are formed as the concave portion. Particularly in this case,a groove width of each concave groove portion is set at 0.005 mm or moreand 0.1 mm or less, and a groove depth of each concave groove portion isset at 0.005 mm or more and 0.05 mm or less. Thereby, in the firstembodiment, the protruded portion can be formed stably on theprovisional element, and the primary molded body can be efficientlymolded. In the second embodiment, the pawl portion can be molded on theengaging element stably, and the molded surface fastener can beefficiently molded.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view illustrating a molded surface fastener tobe manufactured according to Embodiment 1 of the present invention.

FIG. 2 is a perspective view illustrating an engaging element of themolded surface fastener.

FIG. 3 is a plan view illustrating the engaging element only.

FIG. 4 is a front view of the engaging element only viewing from thefront and rear direction (machine direction: MD) of the molded surfacefastener.

FIG. 5 is a cross-sectional view along the V-V line.

FIG. 6 is an enlarged perspective view illustrating a pawl portiondisposed on the engaging element.

FIG. 7 is a schematic view illustrating schematically a manufacturingapparatus of the molded surface fastener.

FIG. 8 is a perspective view illustrating schematically a cylindricalbody disposed on the molding apparatus.

FIG. 9 is a main part schematic view illustrating a position relationbetween a penetration hole and a concave groove portion formed on thecylindrical body.

FIG. 10 is an enlarged cross-sectional view illustrating a main part ofa die wheel in the molding apparatus.

FIG. 11 is a schematic view illustrating a primary molded body moldedwith the molding apparatus.

FIG. 12 is a perspective view illustrating a provisional element of theprimary molded body.

FIG. 13 is a plan view illustrating the provisional element only.

FIG. 14 is a front view illustrating the provisional element onlyviewing from the front and rear direction (MD) of the primary moldedbody.

FIG. 15 is a main part schematic view illustrating a position relationbetween the penetration hole and the concave groove portion of thecylindrical body according to a modification example.

FIG. 16 is a perspective view illustrating an engaging element of amolded surface fastener manufactured in Embodiment 2 of the presentinvention.

FIG. 17 is a plan view illustrating the engaging element only.

FIG. 18 is a main part schematic view illustrating a position relationbetween a penetration hole and a concave groove portion of a cylindricalbody according to Embodiment 2.

FIG. 19 is a perspective view illustrating a provisional element of theprimary molded body molded in Embodiment 2.

FIG. 20 is a plan view illustrating the provisional element only.

FIG. 21 is a perspective view illustrating an engaging element of amolded surface fastener manufactured in Embodiment 3 of the presentinvention.

FIG. 22 is a plan view illustrating an engaging element only.

FIG. 23 is a main part schematic view illustrating a position relationbetween a penetration hole and a concave groove portion of thecylindrical body according to Embodiment 3.

FIG. 24 is a perspective view illustrating the provisional element ofthe primary molded body molded in Embodiment 3.

FIG. 25 is a plan view illustrating the provisional element only.

FIG. 26 is a main part schematic view illustrating a position relationbetween a penetration hole and a concave groove portion of thecylindrical body according to the modification example 1.

FIG. 27 is a main part schematic view illustrating a position relationbetween a penetration hole and a concave groove portion of thecylindrical body according to the modification example 2.

FIG. 28 is a main part schematic view illustrating a position relationbetween a penetration hole and a concave groove portion of thecylindrical body according to the modification example 3.

FIG. 29 is a main part schematic view illustrating a position relationbetween a penetration hole and a concave groove portion of thecylindrical body according to the modification example 4.

FIG. 30 is a main part schematic view illustrating a position relationbetween a penetration hole and a concave groove portion of thecylindrical body according to the modification example 5.

FIG. 31 is a main part schematic view illustrating a position relationbetween a penetration hole and a concave groove portion of thecylindrical body according to the modification example 6.

FIG. 32 a main part schematic view illustrating a position relationbetween a penetration hole and a concave groove portion of thecylindrical body according to the modification example 7.

FIG. 33 a main part schematic view illustrating a position relationbetween a penetration hole and a concave groove portion of thecylindrical body according to the modification example 8.

FIG. 34 is a perspective view illustrating an engaging element of amolded surface fastener manufactured in Embodiment 4 of the presentinvention.

FIG. 35 is a plan view illustrating the engaging element only.

FIG. 36 is a schematic view schematically illustrating a manufacturingapparatus of the molded surface fastener according to Embodiment 4.

FIG. 37 is a perspective view schematically illustrating a cylindricalbody and an auxiliary cylindrical body of the molding apparatus.

FIG. 38 is a main part schematic view illustrating a position relationbetween a penetration hole, a concave groove portion formed on thecylindrical body and a concave portion formed on the auxiliarycylindrical body.

FIG. 39 is a perspective view illustrating a provisional element of theprimary molded body molded with the molding apparatus.

FIG. 40 is a plan view illustrating the provisional element only.

FIG. 41 is a main part schematic view illustrating a position relationbetween a penetration hole, a concave groove portion formed on thecylindrical body and the concave groove portion formed on the auxiliarycylindrical body according to a modification example.

FIG. 42 is a schematic view schematically illustrating a conventionalmolding apparatus.

FIG. 43 is a perspective view illustrating a conventional outer sidescreen and an inner side screen.

FIG. 44 is a cross-sectional view illustrating an enlarged main part ofthe conventional outer side screen and the inner side screen.

MODES FOR CONDUCTING THE INVENTION

Hereinafter, modes for conducting the invention will be described indetail showing embodiments with reference to the drawings. It should benoted that the present invention is not limited to the embodimentsexplained as below, and various changes can be made as long as having asubstantially same structure and similar functional effects to thepresent invention. In each following Embodiment, for example, thenumber, the disposed position and the forming density of the engagingelements disposed on the base portion of the molded surface fastener arenot particularly limited, and can be changed arbitrarily.

Embodiment 1

FIG. 1 is a perspective view illustrating a molded surface fastener tobe manufactured according to Embodiment 1 of the present invention. FIG.2, FIG. 3 and FIG. 4 are a perspective view, a plan view and a frontview illustrating an engaging element of the molded surface fastener.FIG. 4 is a front view of the engaging element only viewing from thefront and rear direction (machine direction: MD) of the molded surfacefastener. FIG. 5 is a cross-sectional view of the engaging element.Further, FIG. 6 is an enlarged main part illustrating a pawl portiondisposed on the engaging element.

In the following descriptions, a front and rear direction regarding amolded surface fastener and a primary molded body is a length directionof the molded surface fastener and the primary molded body molded in along length, as mentioned later. A front and rear direction is adirection along a machine direction (M direction or MD) in which themolded surface fastener or the primary molded body is conveyed in themanufacturing step of the molded surface fastener.

A right and left direction is a width direction perpendicular to thelength direction along an upper surface (or a lower surface) of the baseportion of the molded surface fastener. In this case, the right and leftdirection and the width direction are crossing direction (C direction orCD) perpendicular to the machine direction (MD). An upper and lowerdirection (thickness direction) is a height direction perpendicular tothe length direction, and perpendicular to the upper surface (or thelower surface) of the base portion of the molded surface fastener.

A molded surface fastener 1 of Embodiment 1 as shown in FIG. 1 ismanufactured by molding thermoplastic resin using a manufacturingapparatus 30 having a molding apparatus 40 and a heat press apparatus60, as described later. The molded surface fastener 1 is formed in arectangular sheet shape which is long in the machine direction of themanufacturing apparatus 30 in a plan view. It should be noted that alength dimension and a width dimension of the molded surface fastener 1of the present invention are not particularly limited, and can bechanged arbitrarily by cutting the molded surface fastener 1. It is alsopossible that the molded surface fastener 1 has a shape other than therectangular shape in a plan view.

Further, kinds of synthetic resin forming the molded surface fastener 1is not particularly limited, either. However, as a material of themolded surface fastener 1, thermoplastic resin such as polypropylene,polyester, nylon, polybutylene terephthalate or copolymer thereof may besuitably used. In Embodiment 1, the molded surface fastener 1 is formedof polypropylene.

The molded surface fastener 1 of Embodiment 1 has a thin plate-shapedbase portion 10 and a plurality of engaging elements 20 provided tostand on an upper surface of the base portion 10. The base portion 10 isformed to have a predetermined thickness, and the upper surface and alower surface of the base portion 10 are formed to be flat and parallelto each other.

A plurality of engaging elements 20 are disposed to align along themachine direction (MD) and the crossing direction (CD). In the presentinvention, disposition of the engaging elements 20 is not limited, asmentioned above. For example, the plurality of engaging elements 20 maybe aligned on the base portion 10 in a staggered shape or otherpatterns, or may be provided on the base portion 10 randomly.

Each engaging element 20 in Embodiment 1 has a stem portion 21 standingon the base portion 10, an engaging head portion 22 in a disc shape or aplate shape which is formed to bulge from the entire circumference of anupper end of the stem portion 21 to an outside and two micro pawlportions 23 protruded on an outer peripheral edge part of the engaginghead portion 22.

The stem portion 21 of the engaging element 20 vertically stands on thebase portion 10, and has a frustum shape such that a cross-sectionalarea perpendicular to the upper and lower direction gradually increasesas approaching the base portion 10. Particularly, a lower end part ofthe stem portion 21 in Embodiment 1 is formed to curve such that theouter peripheral surface is spread downward. It should be noted that inthe present invention, the shape of the stem portion 21 is not limitedto the frustum shape, but may be a frustum of pyramid shape such as afrustum of square pyramid shape, a columnar shape or a prismaticcolumnar shape such as a square prismatic column shape.

The engaging head portion 22 of the engaging element 20 has a disc shapespreading in a direction perpendicular to the upper and lower direction.The engaging head portion 22 is integrally formed on the stem portion 21via a boundary 24. Particularly, the engaging head portion 22 ofEmbodiment 1 has a circular shape in a plan view of the engaging element20 viewed from an upper side. The circular shape of the engaging headportion 22 in the plan view has similarity to the circular shape in thelateral cross section perpendicular to the upper and lower direction onthe boundary 24 of the engaging element 20.

In the similarity mentioned here, when a scale of one shape isoverlapped with a scale of the other shape by increasing or decreasingits size for matching, not only a case of congruence in which the bothshapes match completely but a case of overlapping at an area of 85% orhigher, and preferably 90% of higher is included.

Particularly in this case, the engaging head portion 22 is formed tohave a diameter more than 1.0 time and 3.0 times or less of a diameter Dof a circular cross section in the boundary 24 of the engaging element20, and preferably a diameter 1.3 times or more and 2.0 times or less.In a case that the engaging element 22 has a polygonal shape in a planview, the engaging element 22 is formed to have a length of one sidemore than 1.0 time and 3.0 times or less of one arbitrary side of thepolygonal cross section in the boundary 24 of the engaging element 20,and preferably 1.3 times or more and 2.0 times or less.

The engaging head portion 22 of Embodiment 1 has a flat head portion topend surface 22 a disposed parallel to an upper surface of the baseportion 10. On an opposite side of the head portion top end surface 22a, a doughnut-shaped head portion back surface 22 b extending flat fromthe boundary 24 of the stem portion 21 to an outside so as to face thebase portion 10. Further, from an outer periphery of the head portiontop end surface 22 a to the back surface of the head portion 22 b, acurved surface-shaped outer peripheral side surface 22 c is formed.

It should be noted that in the present invention, it is also possiblethat the shape of the engaging head portion 22 has a shape other thanthe circular shape corresponding to the lateral cross sectional shape ofthe stem portion 21. The engaging head portion 22 does not necessarilyneed to bulge from an entire periphery of the upper end of the stemportion 21. Further, in the plan view of the molded surface fastener 1,it is also possible that a central position of the engaging head portion22 in one engaging element 20 is displaced to a central position of thecross section (cross section of the boundary 24) of the upper end of thestem portion 21 each other.

Each engaging element 20 of Embodiment 1 has two pawl portions 23protruded to an outside from the outer peripheral side surface 22 c ofthe engaging head portion 22. The two pawl portions 23 provided at theengaging element 20 protrude to the outside from the outer peripheralside surface 22 c of the engaging head portion 22 along a diameterdirection of the engaging head portion 22 showing a circular shape in aplan view to extend radically based on a center of the engaging headportion 22. Particularly, in a case of Embodiment 1, two pawl portions23 are protruded in an opposite direction to each other from the outerperipheral side surface 22 c of the engaging head portion 22 along aright and left direction (C direction) so as to be point symmetric eachother in a plan view of the engaging element 20.

The pawl portion 23 of Embodiment 1 has a shape hanging down toward atip end as a claw of a bird, as shown in the enlarged view in FIG. 6.The pawl portion 23 has a pawl upper surface sloping downward to the tipend, a pawl back surface (lower surface) disposed facing to the baseportion 10 and a pair of side wall surfaces disposed on both sides ofthe pawl upper surface and the pawl back surface. It should be notedthat in the present invention, a shape of the pawl portion 23 is notparticularly limited as long as formed to protrude from the outerperipheral side surface 22 c of the engaging head portion 22.

In this case, in a base end part of the pawl portion 23 jointing to theengaging head portion 22, a pawl width dimension F (see FIG. 6) betweenthe pair of the side wall surfaces of the pawl portion 23 is set at onethird of a dimension at the boundary 24 of the engaging element 20 in Mdirection (width dimension of the boundary 24) or smaller, preferablyone fifth or smaller and more preferably one seventh or smaller. Sinceeach pawl portion 23 is formed in a micro size having such a pawl widthdimension F, a touch feeling of the molded surface fastener 1 can beless affected by the pawl portion 23 which contributes to improvement ofthe engaging strength of the molded surface fastener 1, as describedlater.

In a case of Embodiment 1, the cross-sectional shape (cross-sectionalshape parallel to the upper surface of the base portion 10) at theboundary 24 of the engaging element 20 is a circular shape, and thedimension at the boundary 24 in M direction is equal to a dimension ofthe diameter at the boundary 24. Meanwhile, in a case that thecross-sectional shape of the engaging element at the boundary is apolygonal shape such as a square shape, the pawl width dimension Fbetween the pair of side wall surfaces of the paw portion is set at onethird of the dimension at the boundary of the engaging element orsmaller, preferably one fifth or smaller, and more preferably oneseventh or smaller.

The pawl portion 23 of Embodiment 1 has a shape such that the pawl widthdimension between the pair of the side wall surfaces is graduallydecreased from the base end part toward a pawl tip end of the pawlportion 23, and a pawl height dimension between the pawl upper surfaceand the pawl back surface is gradually decreased from the base end parttoward the pawl tip end of the pawl portion 23. The tip end of the pawlportion 23 is formed to be at a position lower than the upper surface ofthe engaging head portion 22, and the pawl upper surface of the pawlportion 23 is formed in a curved surface shape sloping downward to thetip end. The pawl back surface of the pawl portion 23 is formed in acurved surface curving in a concave shape. Since the pawl portion 23 isformed in such a shape, an engaging strength of the molded surfacefastener 1 can be effectively increased, and an excellent texture on theupper surface of the molded surface fastener 1 can be stably obtained.

In Embodiment 1, a specific size of the engaging element 20 is set asbelow. For example, a height dimension A from the upper surface of thebase portion 10 of the engaging element 20 in the upper and lowerdirection is set at 0.05 mm or more and 1.5 mm or less and preferably0.2 mm or more and 1.0 mm or less. A diameter B of the engaging headportion 22 in a plan view of the engaging head portion 22 is set at 0.2mm or more and 0.6 mm or less. In a case that the engaging head portion22 has a polygonal shape in a plan view, a dimension of the engaginghead portion 22 in M direction in a plan view of the engaging headportion 22 is set at 0.2 mm or more and 0.6 mm or less.

A height dimension C of the engaging head portion 22 in the engagingelement 20 (i.e. a height dimension from the boundary 24 to the upperend of the engaging head portion 22 of the engaging element 20) is setat 0.01 mm or more and 0.1 mm or less. A diameter D of the engagingelement 20 at the boundary 24 is set at 0.1 mm or more and 0.5 mm orless. In a case that the boundary 24 shows a polygonal shape in a planview, a dimension of the boundary 24 in M direction is set at 0.1 mm ormore and 0.5 mm or less.

A bulging dimension (bulging length) E from a position at the boundary24 of the engaging element 20 at the engaging head portion 22 to theoutermost edge position of the engaging head portion 22 in a directionparallel to the upper surface of the base portion 10 is set at 0.01 mmor more and 0.2 mm or less and preferably 0.02 mm or more and 0.1 mm orless. A bulging angle θ formed by the outer peripheral side surface ofthe stem portion 21 and the back surface of the head portion 22 b of theengaging head portion 22 in the engaging element 20 is set at 90° orlarger and 140° or smaller.

A pawl width dimension F between the pair of the side wall surfaces inthe base end part of the pawl portion 23 is set at 0.01 mm or more and0.10 mm or less and preferably 0.03 mm or more and 0.08 mm or less. Apawl length dimension from a boundary position between the back surfaceof the head portion 22 b of the engaging head portion 22 and the pawlback surface of the pawl portion 23 to a tip end position of the pawlportion 23 is set at 0.01 mm or more and 0.04 mm or less.

The molded surface fastener 1 of Embodiment 1 having the above-mentionedstructure is manufactured using a manufacturing apparatus as shown inFIG. 7.

The manufacturing apparatus 30 has a molding apparatus 40 conducting aprimary molding step and a heat press apparatus 60 which heats andpresses a primary molded body 11 molded in the primary molding step.

The molding apparatus 40 of Embodiment 1 has a die wheel 41 driverotating in one direction (anticlockwise direction in the drawings), anextrusion nozzle 45 disposed facing to a circumferential surface of thedie wheel 41 and extruding molten synthetic resin material continuouslyand a pickup roller 46 disposed on a downstream side of the extrusionnozzle 45 in the rotation direction of the die wheel 41.

The die wheel 41 has a cylindrical body 42 which serves as a mold memberand a rotation driving roller 44 disposed as a driving part to rotatethe cylindrical body 42 in one direction. Such a cylindrical body 42 isalso called as a sleeve or cylindrical mold. In the rotation drivingroller 44, a cooling jacket (not shown in the drawings) to distributecooling liquid is provided, and can cool the primary molded body 11molded on the circumferential surface of the die wheel 41 efficiently.

In the cylindrical body 42 of the die wheel 41, a plurality ofpenetration holes 47 penetrating from an outer peripheral surface to aninner peripheral surface along a diameter direction of the cylindricalbody 42 and a plurality of concave groove portions 51 which serve asconcave portions concaved linearly in the inner peripheral surface ofthe cylindrical body 42 parallel to a central axis direction of thecylindrical body 42 are provided as shown in FIGS. 8 to 10. In thecylindrical body 42, the plurality of penetration holes 47 are providedas cavities forming primary stem portions 71 of the primary molded body11, as described later, and the plurality of concave groove portions(concave portions) 51 are provided as cavities forming protrudedportions 73 of the primary molded body 11, as described later.

The cylindrical body 42 of Embodiment 1 is produced by forming theprimary cylindrical body 42 in a cylindrical shape, and thereafterforming the plurality of penetration holes 47 and the plurality ofconcave groove portions 51 at predetermined positions of the primarycylindrical body 42.

In this case, the primary cylindrical body 42 is produced from knownmetal such as nickel and stainless steel. For example, a seamlessprimary cylindrical body 42 is produced by forming a metal plate havinga predetermined thickness and length by extending by applying pressure,rolling the metal plate in a cylindrical shape and welding it.

As a method for processing the plurality of the penetration holes 47 andthe plurality of concave groove portions 51 to the produced primarycylindrical body 42, a known general technique can be used.

For example, laser processing, electron beam processing, machineprocessing including holing processing and etching processing can beused. It is also possible that the cylindrical body 42 of Embodiment 1is produced by forming the plurality of penetration holes 47 and theplurality of concave groove portions 51 at predetermined positions ofthe metal plate having a flat plate shape, and thereafter rolling andwelding the metal plate in a circular cylindrical shape. In the presentinvention, a method of producing the cylindrical body 42, a size and athickness of the cylindrical body 42, and a shape and disposition of thepenetration holes 47 and the concave groove portions 51 provided on thecylindrical body 42 are not particularly limited.

In the cylindrical body 42 of Embodiment 1, the plurality of penetrationholes 47 are formed corresponding to a disposition of the engagingelements 20 of the molded surface fastener 1 which is to bemanufactured. For example, the penetration holes 47 of Embodiment 1 areformed at regular intervals at predetermined pitches in acircumferential direction which is M direction (MD) of the cylindricalbody 42, and are formed at regular intervals at predetermined pitches inC direction (CD) parallel to the central axis of the cylindrical body42.

The plurality of concave groove portions 51 are concaved linearly in theinner peripheral surface of the cylindrical body 42 along C direction(CD) parallel to the central axis of the cylindrical body 42. Theconcave groove portion 51 has a size in which synthetic resin formingthe molded surface fastener 1 can flow in a molten state. Particularlyin the case of Embodiment 1, a position relation of the penetrationholes 47 and the concave groove portions 51 provided on the cylindricalbody 42 is such that the concave groove portion 51 crosses the circularouter peripheral edge of the penetration hole 47 formed on thecylindrical body 42 and communicates to the penetration hole 47, asshown in FIG. 9.

The concave groove portions 51 are formed at a position overlapped witha straight line along C direction connecting diameters of the pluralityof penetration holes 47 aligned in C direction to have predeterminedintervals in a circumferential direction which is M direction. FIG. 9 isa schematic view viewing a part of the cylindrical body 42 from theouter peripheral surface side, and the concave groove portions 51 arerepresented with a dashed line, and groove bottom surfaces of theconcave groove portions 51 are shown in a gray color (the same appliesto FIGS. 15, 18 and 23).

As shown in FIG. 9, the relative position of the concave groove portions51 with respect to the penetration holes 47 can be precisely adjusted byproviding the penetration holes 47 and the concave groove portions 51 inone cylindrical body 42. Therefore, when the primary molded body 11 ismolded as described later, a provisional element 70 having apredetermined shape can be molded stably, and as a result, the moldedsurface fastener 1 having a plurality of engaging elements 20 having apredetermined shape as shown in FIG. 2 can be stably manufactured.

It should be noted that in Embodiment 1, the forming pitches of thepenetration holes 47 which are provided on the cylindrical body 42 in acircumferential direction and the forming pitches of the concave grooveportions 51 concaved on the inner peripheral surface in thecircumferential direction are set so that the positions of thepenetration holes 47 and the concave groove portions 51 correspond toeach other, as mentioned above. However, it is also possible in thepresent invention that the forming pitches of the penetration holes 47and the forming pitches of the concave groove portions 51 are set not tocorrespond to each other.

For example, by providing a plurality of concave groove portions 51 atsmaller forming pitches than the forming pitches of the penetrationholes 47, two or more pawl portions can be stably formed on the engaginghead portion of each engaging element. On the other hand, by providing aplurality of concave groove portions 51 at larger forming pitches thanthe forming pitches of the penetration holes 47, a molded surfacefastener having both of the engaging element on which the pawl portionis protruded on the engaging head portion and the engaging element onwhich the pawl portion is not provided on the engaging head portion canbe manufactured.

Each concave groove portion 51 provided in Embodiment 1 has a flatgroove bottom surface and a pair of groove side wall surfaces disposedto face parallel to each other so that a cross section in a directionperpendicular to the central axis is square-shaped. In this case, agroove width of each concave groove portion 51 is set at 0.005 mm ormore and 0.10 mm or less, and preferably 0.01 mm or more and 0.08 mm orless. A groove depth of each concave groove portion 51 is set at 0.005mm or more and 0.05 mm or less, preferably 0.005 mm or more and 0.03 mmor less, and more preferably 0.01 mm or more and 0.025 mm or less.

By setting the groove width of the concave groove portion 51 at 0.005 mmor larger and the groove depth at 0.005 mm or larger, when molding theprimary molded body 11, molten synthetic resin can flow in the concavegroove portion 51 from each penetration hole 47 of the cylindrical body42 smoothly. Further, the pawl portions 23 of the solidified primarymolded body 11 can be demolded from the concave groove portion 51stably.

Meanwhile, by setting the groove width of the concave groove portion 51at 0.10 mm or smaller and the groove depth at 0.05 mm or smaller, themicro pawl portions 23 can be formed stably as mentioned above on eachengaging element 20 of the molded surface fastener 1. In this caseparticularly, the groove width of the concave groove portion 51 is setat a size of one third of a dimension of the penetration hole 47 in Mdirection provided on the cylindrical body 42 (a diameter dimension ofthe penetration hole 47 in a case of Embodiment 1) or smaller,preferably one fifth or smaller, and more preferably one seventh orsmaller. It is also possible that the concave groove portion 51 formedon the inner peripheral surface of the cylindrical body 42 is formed tohave a cross section in a substantially U-shape.

The pickup rollers 46 of Embodiment 1 has a pair of an upper sideholding roller 46 a and a lower side holding roller 46 b which hold theprimary molded body 11 formed on the outer peripheral surface of the diewheel 41 from upper and lower sides. A surface layer made of elastomersuch as polyurethane elastomer which is not shown in the drawings isprovided on the outer peripheral surface part of the upper side holdingroller 46 a on which the primary molded body 11 is contacted and on theouter peripheral surface part of the lower side holding roller 46 b onwhich the primary molded body 11 is contacted.

The upper side holding roller 46 a and the lower side holding roller 46b are disposed facing to each other at a predetermined interval. Theupper side holding roller 46 a and the lower side holding roller 46 brotate in a predetermined direction and a predetermined speedrespectively, thereby the primary molded body 11 can be conveyed towardthe heat press apparatus 60 smoothly while peeling off the primarymolded body 11 continuously from the die wheel 41.

At the pickup rollers 46, just after the primary molded body 11 ispeeled off from the die wheel 41, the primary molded body 11 is heldwith the upper side holding roller 46 a and the lower side holdingroller 46 b, thereby the protruded portions (provisional pawl portions)73 of the provisional elements 70 molded on the die wheel 41 can bedeformed so as to protrude to be parallel to the upper surface of thebase portion 10 or to decline or curve downward to the base portion 10.

A heat press apparatus 60 of Embodiment 1 has an upper and lower pair ofpress rollers (calender rollers) 61, 62 disposed on a downstream side ofthe pickup rollers 46, and the upper side press roller and the lowerside press roller are disposed to face each other at a predeterminedinterval. In this case, the interval between the upper side press roller61 and the lower side press roller 62 can be adjusted with a heightadjusting means which is not shown in the drawings, and is adjustedcorresponding to a height dimension from the lower surface (backsurface) of the base portion 10 to the head portion top end surface 22 aof the engaging head portion 22 in the engaging element 20 of themolding surface fastener 1 to be manufactured. In Embodiment 1,particularly, the interval between the upper side press roller 61 andthe lower side press roller 62 is adjusted a little smaller than theinterval between the upper side holding roller 46 a and the lower sideholding roller 46 b of the pickup rollers 46.

The upper side press roller 61 has a heat source inside which is notshown in the drawings, and can heat and maintain the surface of theupper side press roller 61 at a predetermined temperature. In this case,the temperature of the surface of the upper side press roller 61 to beheated and maintained is not limited in particular, and set at thetemperature capable of softening synthetic resin forming the moldedsurface fastener 1, for example. Specifically, it is set at thetemperature at the melting point of the synthetic resin forming theprimary molded body 11 minus 40° C. or higher and the temperature at themelting point minus 10° C. or lower. The upper side press roller 61 isdisposed to rotate anticlockwise in FIG. 7. The outer peripheral surfaceof the upper side press roller 61 serves as a part pressing the heatedprovisional elements 70 of the primary molded body 11 molded in theprimary molding step from above.

The lower side press roller 62 is disposed to rotate clockwise in FIG. 7to be a supporting surface supporting the conveyed primary molded body11 from the lower side. Instead of the upper side press roller 61 and/orthe lower side press roller 62, it is possible in the present inventionto use an upper side belt mechanism and/or a lower side belt mechanismwhich are not shown in the drawings. In this case, each of the upperside and the lower side belt mechanisms has an endless belt and a rightand left pair of rotation rollers which the endless belt is wound aroundand rotate the endless belt in one direction.

In manufacturing the molded surface fastener 1 using the manufacturingapparatus 30 having the molding apparatus 40 and the heat pressapparatus 60 as mentioned above, the primary molding step is conductedfirst to mold the primary molded body 11 using the molding apparatus 40.In the primary molding step, molten synthetic resin material iscontinuously extruded from an extrusion nozzle 45 toward acircumferential surface of the die wheel 41.

At this time, the die wheel is drive-rotating in one direction, and thebase portion 10 of the molded surface fastener 1 is continuously moldedbetween the extrusion nozzle 45 and the die wheel 41 by extruding thesynthetic resin material on the circumferential surface. In this case,an interval between the extrusion nozzle 45 and the die wheel 41 isadjusted to a size corresponding to a thickness dimension of the baseportion 10 of the molded surface fastener 1 to be manufactured.

At the same time of molding the base portion 10, a plurality ofprovisional elements 70 as shown in FIGS. 11 to 14 are molded integrallyon the base portion 10 by the above-mentioned cylindrical body 42disposed on the die wheel 41 as above. Thereby, the primary molded body11 is produced.

Here, the primary molded body 11 (also referred to as a preliminarymolded body) molded with the molding apparatus 40 of Embodiment 1 has athin plate-shaped base portion 10 and the plurality of provisionalelements 70 standing on the upper surface of the base portion 10. Thebase portion 10 of the primary molded body 11 serves as the base portion10 of the molded surface fastener 1 without change.

The provisional element 70 formed at the primary molded body 11 is apart to be the engaging element 20 of the molded surface fastener 1 bypress molding in the secondary molding step. In this case, eachprovisional element 70 has a primary stem portion 71 standing on thebase portion 10 and having a frustum shape, and two protruded portions(provisional pawl portions) 73 protruded in a tongue shape to bulgeoutward from the outer peripheral side surface of an upper end part ofthe primary stem portion 71.

The primary stem portion 71 is molded by filling the penetration hole 47drilled on the cylindrical body 42 with synthetic resin, and has afrustum shape such that a cross-sectional area perpendicular to theupper and lower direction is gradually increased as approaching to thebase portion 10. An upper end surface of the primary stem portion 71 isformed to be a flat surface. The upper end surface of the primary stemportion 71 and the upper surface of two right and left protrudedportions form a single flat surface.

The primary stem portion 71 of Embodiment 1 becomes the stem portion 21and the engaging head portion 22 of the molded surface fastener 1 bypressing the provisional elements 70 from above and deforming the upperend part of the primary stem portion 71 in the secondary molding step.The lower end part of the primary stem portion 71 has a similar shape tothe lower end part of the stem portion 21. It is also possible that theprimary stem portion 71 is formed in a frustum of pyramid shape such asa frustum of square pyramid shape, a columnar shape or a prismaticcolumnar shape such as a square prismatic column, depending on the shapeof the stem portion 21 of the molded surface fastener 1 to bemanufactured.

The protruded portion (provisional pawl portion) 73 is molded such thatthe synthetic resin flows in the concave groove portion 51 provided onthe inner peripheral surface of the cylindrical body 42 from thepenetration hole 47 of the cylindrical body 42 in the primary moldingstep. In this case, the two protruded portions 73 are protruded from theouter peripheral side surface of the primary stem portion 71 along Cdirection. The molded protruded portion 73 has a pole shape showing arounded cross section due to contraction, etc.

In this case, molding of the protruded portion 73 is conducted not byfilling the entire concave groove portion 51 provided on the innerperipheral surface of the cylindrical body 42 with the synthetic resin,but such that the synthetic resin flowing into the concave grooveportion 51 from the penetration hole 47 of the cylindrical body 42intrudes to a part of the concave groove portion 51 (a distance from thepenetration hole 47 at a degree from 0.01 mm to 0.04 mm, for example)along the concave groove portion 51 so as to overflow a little from aforming region of the penetration hole 47. That is, the synthetic resinbecomes easier to be cooled by flowing into the concave groove portion51 from the penetration hole 47 of the cylindrical body 42, thereby itis solidified when it enters at a predetermined distance in the concavegroove portion 51 from the penetration hole 47 to form the protrudedportion 73. The protruded portion 73 molded in the primary molding stepis a part serving as the pawl portion 23 of the molded surface fastener1 by pressing the provisional element 70 from above in the secondarymolding step.

The primary molded body 11 molded in the primary molding step isproduced such that molten synthetic resin is extruded from the extrusionnozzle 45, fills the penetration hole 47 of the cylindrical body 42 andflows in the concave groove portion 51, and further the synthetic resinis cooled and solidified while being supported on the outer peripheralsurface of the die wheel 41 and half-turning.

Thereafter, the primary molded body 11 is continuously peeled off fromthe outer peripheral surface of the die wheel 41 by the pickup rollers46. At this time, the protruded portion 73 of the primary molded body 11is formed by being pulled out from the concave groove portion 51 of thecylindrical body 42 through the penetration hole 47 smoothly while beingdeformed.

For example, when the protruded portion 73 of the primary molded body 11is pulled out of the concave groove portion 51 of the cylindrical body42, it deforms to a shape curved or inclined upward so as to inclineupward to a protruded tip end from the outer peripheral side surface ofthe primary stem portion 71 by exiting while sliding contacting with theinner peripheral surface of the penetration hole 47 of the cylindricalbody 42, in some cases. However, just after being peeled off from thedie wheel 41, the primary molded body 11 is held by the upper sideholding roller 46 a and the lower side holding roller 46 b of the pickuprollers 46 disposed apart at a predetermined interval each other. Atthis time, the protruded portion 73 of the provisional element 70 whichis curved or sloped upward is bent and deformed partially (plasticallydeformed) by being pressed from above by the upper side holding roller46 a. As a result, the protruded portion 73 of the provisional element70 can be protruded parallel to the upper surface of the base portion 10or to be sloped or curved downward to the base portion 10.

Therefore, in the primary molded body 11 obtained by passing the pickuprollers 46, the protruded portion 73 of each provisional element 70 isformed, in a front view viewing the provisional element 70 from Mdirection and with respect to the upper and lower direction, to beprotruded from the outer peripheral side surface of the primary stemportion 71 in a horizontal direction substantially parallel to the uppersurface of the base portion 10, or to be protruded downward rather thanthe horizontal direction.

The primary molded body 11 peeled off from the die wheel 41 isthereafter conveyed to the heat press apparatus 60 conducting thesecondary molding step, and introduced between the upper side pressroller 61 and the lower side press roller 62 of the heat press apparatus60.

In the secondary molding step, when the primary molded body 11 passesbetween the upper side press roller 61 and the lower side press roller62, at least an upper end part of each provisional element 70 of theprimary molded body 11 is heated and softened by the upper side pressroller 61. At this time, a temperature of the roller circumferentialsurface in the upper side press roller 61 is, as mentioned above, set atthe predetermined temperature of the melting point of the syntheticresin of the primary molded body 11 minus 40° C. or higher and themelting point minus 10° C. or lower. At the same time, the base portion10 of the primary molded body 11 is supported from the lower side by thelower side press roller 62, and each provisional element 70 of theprimary molded body 11 is pressed from above by the upper side pressroller 61, thereby the upper end part of the provisional element 70 iscompressed.

Thereby, the upper end part of the primary stem portion 71 and the rightand left protruded portions 73 in the provisional element 70 arethermally deformed, and the engaging head portion 22 having a headportion top end surface 22 a flattened by the outer peripheral surfaceof the upper side press roller 61 and the stem portion 21 are molded. Atthe same time, two pawl portions 23 protruded on the outer peripheralside surface 22 c of the engaging head portion 22 is formed from theprotruded portion 73 of the provisional element 70.

At this time, the protruded portion 73 formed on the provisional element70 of the primary molded body 11 is, regarding the upper and lowerdirection, protruded in the horizontal direction or the lower directionrather than the horizontal direction from the outer peripheral sidesurface of the primary stem portion 71, as mentioned above. Theprovisional element 70 is pressed from above by the upper side pressroller 61 in the secondary molding step, thereby the pawl portion 23which is provided by deforming the protruded portion 73 is formed toprotrude from the outer peripheral side surface 22 c of the engaginghead portion 22 to curve (or slope) downward to the base portion 10.Thus, the molded surface fastener 1 of Embodiment 1 shown in FIG. 1 isstably, smoothly and efficiently manufactured.

Thereafter, the manufactured molded surface fastener 1 which is long inthe machine direction is conveyed to a cutting part which is not shownin the drawings, and cut at predetermined length at the cutting part andcollected, or the long molded surface fastener 1 is wound around acollecting roller and the like in a roll shape and collected in the longlength state.

In the molded surface fastener 1 of Embodiment 1 manufactured as above,two micro pawl portions 23 protruded along C direction are provided onthe engaging head portion 22 of each engaging element 20. Particularly,the pawl portion 23 of Embodiment 1 has a concave-shaped pawl backsurface curving downward to be lower than the back surface of the headportion 22 b of the engaging head portion 22. In other words, the mosttip end part of the pawl portion 23 of Embodiment 1 exists at a positionlower than the head portion top end surface 22 a of the engaging headportion 22. Thereby, when a loop which is to be the engaging element 20of a female surface fastener is engaged with the molded surface fastener1 of Embodiment 1, the loop of the female surface fastener is easy to behooked by the pawl portion 23 of each engaging element 20, and the loopis less likely to be drop off from each engaging element.

Accordingly, the molded surface fastener 1 of Embodiment 1 has a higherengaging strength (peeling strength) than conventional general moldedsurface fasteners without the pawl portions 23, and the engaging statewith respect to the female surface fastener can be stably maintained.

In addition, in the molded surface fastener 1 of Embodiment 1, the headportion top end surface 22 a and the outer peripheral side surface 22 cof the engaging head portion 22 in each engaging element 20 are formedto be a smooth continuous surface. The pawl portion 23 provided toenhance the engaging strength is formed in a smaller size with respectto the engaging head portion 22, and the upper surface of the pawlportion 23 is formed in a curved surface sloping downward to the pawltip end.

Thereby, a touch feeling of the molded surface fastener 1 can be lessaffected by the pawl portions 23. As a result, the molded surfacefastener 1 of Embodiment 1 can have an excellent texture from whichsmooth touch feeling and a soft and supple touch feeling can be obtainedwhen the molded surface fastener 1 is touched on the upper surface sideon which the engaging elements 20 stand.

The molded surface fastener 1 of Embodiment 1 having high engagingstrength and excellent texture as mentioned above is suitably used forgoods to be put on a body such as disposable diapers, diaper covers forbabies, supporters to protect limb joints, corsets for backache andgloves.

In the above Embodiment 1, the concave groove portions 51 concaved onthe inner peripheral surface of the cylindrical body 42 of the moldingapparatus 40 are disposed at a position relation as shown in FIG. 9 withrespect to the penetration holes 47 drilled on the cylindrical body 42.That is, each concave groove portion 51 is formed continuously along Cdirection on an entire length between the penetration holes 47 adjacentin C direction so as to connect diameters along C direction of thepenetration holes 47 which are lined in C direction. However, inmanufacturing the molded surface fastener 1 of Embodiment 1, it is alsopossible to use a molding apparatus having a cylindrical body 42 a onwhich the penetration holes 47 and the concave groove portions 51 a tobe concave portions are formed at a position relation as shown in FIG.15, instead of the cylindrical body 42 as shown in FIG. 9.

The penetration holes 47 of the cylindrical body 42 a shown in FIG. 15are drilled similarly to the penetration holes 47 provided on thecylindrical body 42 shown in FIG. 9. A plurality of concave grooveportions (concave portions) 51 a shown in FIG. 15 are concaved on theinner peripheral surface of the cylindrical body 42 along C direction.The concave groove portions 51 have a size capable of allowing syntheticresin in a molten state forming the molded surface fastener 1 to flowin. In this case, a shape and dimension of a cross section of theconcave groove portion 51 a in FIG. 15 is the same as those of theconcave groove portion 51 concaved on the cylindrical body 42 shown inFIG. 9.

The concave groove portions 51 a of FIG. 15 are formed along C directionso as to cross circular-shaped outer peripheral edges of the penetrationholes 47 and continue to the diameters of the penetration holes 47, andat predetermined pitches in a circumferential direction which is Mdirection. Further, the concave groove portions 51 a of FIG. 15 areformed from the circular-shaped outer peripheral edge of eachpenetration hole 47 along C direction at a predetermined length to rightand left, and between the concave groove portions 51 a adjacent in Cdirection, a flat surface (flat curved surface) on which the concavegroove portion 51 a is not formed is provided as ano-concave-groove-formed portion.

In this case, a length of the concave groove portion 51 a from thecircular-shaped outer peripheral edge of the penetration hole 47 ispreferably corresponded to the protruded length of the protruded portion73 provided on the provisional element 70 of the primary molded body 11.It should be noted that the cylindrical body 42 a having the penetrationholes 47 and the concave groove portions 51 a as shown in FIG. 15 can beproduced using the same method and means as those of the cylindricalbody 42 of Embodiment 1 as shown in FIG. 9.

Molding of the primary molded body 11 is conducted in the primary moldedprocess using the cylindrical body 42 a on which the penetration holes47 and the concave groove portions 51 a are formed at a positionrelation as shown in FIG. 15, thereby a size (particularly, protrudedlength) of the protruded portion 73 formed on the provisional element 70of the primary molded body 11 can be stabilized, compared with a case ofusing the cylindrical body 42 as shown in FIG. 9.

Therefore, the primary molded body 11 having a plurality of provisionalelements 70 on which the protruded portions 73 having a uniformprotruded length from the primary stem portions 71 are formed can bestably produced. Further, the secondary molding step as above isconducted to the obtained primary molded body 11, thereby the moldedsurface fastener 1 having the engaging elements 20 on which the pawlportions 23 having the relatively uniform protruded amount from theengaging head portion 22 are provided can be stably manufactured.

In the above Embodiment 1, the primary molded body 11 on which aplurality of provisional elements 70 stand on the base portion 10 asshown in FIGS. 11 to 14 is molded, and thereafter, the secondary moldingstep is conducted to the primary molded body 11, thereby the moldedsurface fastener 1 as shown in FIG. 1 is manufactured. However, in thepresent invention, it is also possible to manufacture a molded surfacefastener having the plurality of provisional elements 70 as the engagingelements as they are such that the primary molded body 11 on which theplurality of provisional elements 70 stand on the base portion 10 asshown in FIGS. 11 to 14 are directly cooled, for example. That is, theprimary molded body 11 molded by the molding apparatus 40 in the primarymolding step as above can be provided as the molded surface fastenerwithout change.

In this case, each engaging element of the manufactured molded surfacefastener has a different shape from the engaging element 20 shown inFIG. 2, and has the primary stem portion 71 of the provisional element70 having a frustum shape as a stem portion as shown in FIGS. 11 to 14,and two protruded portions 73 of the provisional element 70 are providedas micro pawl portions (i.e. the engaging element 70 in this case hasthe stem portion 71 and two pawl portions 73). In each engaging element,the engaging head portion 22 as in the engaging element 20 as shown inFIG. 2 is not provided.

Therefore, the pawl portion (i.e. the protruded portion 73 ofEmbodiment 1) of the engaging element is, in a plan view of the engagingelement, protruded from the upper end outer peripheral edge of the stemportion (i.e. primary stem portion 71 of Embodiment 1) in a frustumshape to an outside in a horizontal direction parallel to the uppersurface of the base portion 10 or downward on the lower side rather thanthe horizontal direction.

In this case, when the molded surface fastener (i.e. the primary moldedbody 11 of Embodiment 1) is peeled off from the outer peripheral surfaceof the die wheel 41 by the pickup rollers 46 continuously, the right andleft pawl portions (i.e. protruded portions 73 of Embodiment 1) of theengaging element can be pressed from above to be partially plasticallydeformed by the upper side holding roller 46 a of the pickup rollers 46.As a result, the protruded direction of the right and left pawl portionscan be stably directed to the horizontal direction or on the lower siderather than the horizontal direction.

Further, it is also possible that after the molded surface fastener(i.e. the primary molded body 11 of Embodiment 1) is peeled off by thepickup rollers 46, the molded surface fastener is cooled while beingconveyed horizontally with a conveying apparatus which is not shown inthe drawings, for example. Thereby, the right and left pawl portions(i.e. the protruded portions 73 of Embodiment 1) are partially furtherbent and deformed so as to hang downward by its own weight, and theprotruded direction of the pawl portions can be directed on the lowerside rather than the horizontal direction parallel to the upper surfaceof the base portion 10.

Further, the pawl portions of the engaging element can be curved anddeformed downward further intentionally by providing a heating part onan upper part of the conveying apparatus or blowing hot air from aboveof the molded surface fastener conveyed by the conveying apparatus.Thereby, the molded surface fastener in which the pawl portions areprotruded to be bent or curved downward rather than the horizontaldirection toward the base portion 10 can be more stably manufactured.

In the case of the molded surface fastener manufactured as above, theupper end surface of the stem portion (i.e. the primary stem portion 71of Embodiment 1) is formed to be a circular shape. The pawl widthdimension of the micro pawl portion (i.e. the protruded portion 73 ofEmbodiment 1) is set at half or smaller of the diameter of thecircular-shaped upper end surface of the stem portion, preferably onethird or smaller, and more preferably one fourth or smaller.

The specific size of the engaging element in this case is set as below.A height dimension A of the engaging element is set at 0.05 mm or moreand 1.5 mm or less, and preferably 0.2 mm or more and 1.0 mm or less.The diameter of the circular-shaped upper end surface of the stemportion is set at 0.1 mm or more and 0.5 mm or less. The pawl widthdimension F of the pawl portion is set at 0.01 mm or more and 0.10 mm orless, and preferably 0.03 mm or more and 0.08 mm or less. The pawllength dimension of the pawl portion is set at 0.01 mm or more and 0.04mm or less.

The molded surface fastener having the provisional elements 70 ofEmbodiment 1 as above as the engaging elements can have a high peelingstrength due to the micro pawl portions with respect to a female surfacefastener. Further, excellent texture and touch feeling as same as thoseof Embodiment 1 can be stably obtained. In the present invention, eachprimary molded body molded in the primary molding step can be used as itis as the molded surface fastener in not only Embodiment 1 but alsoEmbodiments 2 to 4, as described later.

Embodiment 2

FIG. 16 is a perspective view illustrating an engaging element of amolded surface fastener manufactured in Embodiment 2. FIG. 17 is a planview illustrating the engaging element only.

In the molded surface fastener 2 of Embodiment 2, the number of the pawlportions 23 provided on the engaging head portion 22 of each engagingelement 20 a is four which is different from the case of Embodiment 1 asabove. However, except changing the forming number of the pawl portions23, the molded surface fastener 2 of Embodiment 2 is formedsubstantially same as the molded surface fastener 1 explained in theabove-mentioned Embodiment 1.

Therefore, in Embodiment 2, Embodiments 3 and 4 as well as eachmodification example which are described later, structures which aredifferent from the molded surface fastener 1 of the above-mentionedEmbodiment 1 are mainly explained, and parts and members havingsubstantially same structures as the above-mentioned molded surfacefastener 1 of Embodiment 1 are not explained but represented with thesame reference signs.

The molded surface fastener 2 of Embodiment 2 has a plurality ofengaging elements 20 a standing vertically on an upper surface of a thinplate-shaped base portion 10. The plurality of engaging elements 20 aare disposed to align along M direction (MD) and C direction (CD). Eachengaging element 20 a has a stem portion 21 standing on the base portion10, an engaging head portion 22 integrally formed on the stem portion 21and having a disc shape and four pawl portions 23 protruded on an outerperipheral edge part of the engaging element 22. In this case, the stemportion 21 and the engaging head portion 22 of Embodiment 2 are formedsubstantially same as the stem portion 21 and the engaging head portion22 of the engaging element 20 of Embodiment 1 as above.

In the engaging element 20 a of Embodiment 2, the four pawl portions 23are protruded along the diameter direction of the engaging element 22from the outer peripheral side surface 22 c of the engaging head portion22 in M direction and C direction. These four pawl portions 23 aredisposed regularly at positions of 0°, 90°, 180° and 270° based on acenter of the engaging head portion 22 showing a circular shape in aplan view of the engaging element 20 a as shown in FIG. 17. It should benoted that a shape and a size of each pawl portion 23 formed inEmbodiment 2 are the same as those of the pawl portion 23 provided onthe molded surface fastener 1 of Embodiment 1 as mentioned above.

In Embodiment 2, the molded surface fastener 2 having the engagingelement 20 a on which the four pawl portions 23 are disposed as above ismanufactured using the manufacturing apparatus 30 having the moldingapparatus 40 and the heat press apparatus 60 as shown in FIG. 7, as inthe case of Embodiment 1 as above. In the case of Embodiment 2, acylindrical body 42 a disposed on the die wheel 41 of the moldingapparatus 40 has a different structure from the cylindrical body 42 usedin the above-mentioned Embodiment 1 in order to provide four pawlportions 23 on each engaging element 20 a.

The cylindrical body (sleeve) 42 a used in Embodiment 2 has, as shown inFIG. 18, a plurality of penetration holes 47 penetrating along thediameter direction of the cylindrical body 42 a from the outerperipheral surface to the inner peripheral surface, and a plurality ofconcave groove portions 52 concaved on the inner peripheral surface ofthe cylindrical body 42 a to be a concave portion. The penetration holes47 formed on the cylindrical body 42 a of Embodiment 2 are formed assame as the penetration holes 47 formed on the cylindrical body 42 ofEmbodiment 1 as above. That is, the penetration holes 47 of Embodiment 2are formed to penetrate from the outer peripheral surface to the innerperipheral surface of the cylindrical body 42 a, and are formed atpredetermined pitches in M direction (circumferential direction) and Cdirection of the cylindrical body 42 a.

The concave groove portion (concave portion) 52 formed on the innerperipheral surface of the cylindrical body 42 a of Embodiment 2 has aplurality of first concave groove portions 52 a formed along C directionand a plurality of second concave groove portions 52 b formed along Mdirection (circumferential direction) in order to provide the four pawlportions 23 on each engaging element 20 a of the molded surface fastener2.

The first concave groove portions 52 a in C direction and the secondconcave groove portions 52 b in M direction communicate to thepenetration holes 47 formed on the cylindrical body 42 a. The firstconcave groove portions 52 a and the second concave groove portions 52 bare formed to have predetermined pitches on a straight line along Cdirection and M direction, respectively so as to connect diameters ofthe plurality of penetration holes 47 lined in C direction and Mdirection. Therefore, an imaginary extension line obtained by extendingthe first concave groove portions 52 a into the penetration holes 47 andan imaginary extension line obtained by extending the second concavegroove portions 52 b into the penetration holes 47 have a relation to beperpendicular to each other at a central position of each penetrationhole 47.

It should be noted that in Embodiment 2, forming pitches of thepenetration holes 47 provided on the cylindrical body 42 a and formingpitches of the concave groove portions 52 in a circumferential directioncorrespond to each other, but the cylindrical body can be formed suchthat forming pitches of the penetration holes 47 and the forming pitchesof the first concave groove portions 52 a and the second concave grooveportions 52 b do not correspond to each other.

The first concave groove portions 52 a and the second concave grooveportions 52 b of Embodiment 2 are continuously formed on an entirelylength between the adjacent penetration holes 47 along C direction and Mdirection. It should be noted that the first concave groove portions 52a and the second concave groove portions 52 b of Embodiment 2 may beformed to extend from the circular-shaped outer peripheral edge of eachpenetration hole 47 at a predetermined length only along C direction andM direction, as explained in Embodiment 1 as above referring to FIG. 15.In this case, between the adjacent first concave groove portions 52 a inC direction and the adjacent second concave groove portions 52 b in Mdirection, a flat surface on which the first concave groove portions 52a and the second concave groove portions 52 b are not formed as ano-concave-groove-formed portion.

In Embodiment 2, a primary molded body 12 on which a plurality ofprovisional elements 70 a stand on the base portion 10 as shown in FIGS.19 and 20 is molded by conducting the primary molding step using themolding apparatus 40 having the cylindrical body 42 a on which thepenetration holes 47, the first concave groove portions 52 a and thesecond concave groove portions 52 b are formed as shown in FIG. 18. Inthis case, each provisional element 70 a has a primary stem portion 71standing on the base portion 10 and having a frustum shape and fourprotruded portions 73 extending to bulge to an outside from the outerperipheral side surface of the upper end part of the primary stemportion 71.

The four protruded portions 73 disposed on one provisional element 70 aare molded such that synthetic resin flows in the first concave grooveportions 52 a and the second concave groove portions 52 b concaved onthe inner peripheral surface of the cylindrical body 42 a from thepenetration holes 47 of the cylindrical body 42 a in the primary moldingstep. Therefore, the four protruded portions 73 are formed to protrudefrom the outer peripheral side surface of the primary stem portion 71along the diameter direction of the circular-shaped upper surface of theprimary stem portion 71 in C direction and M direction.

And, the primary molded body 12 in Embodiment 2 having the provisionalelements 70 a as shown in FIGS. 19 and 20 is then conveyed to the heatpress apparatus 60 in which the secondary molding step is conducted, andeach provisional element 70 a is heated and pressed from above by theupper side press roller 61 as in the case of Embodiment 1 as above.

Thereby, the molded surface fastener 2 having the plurality of engagingelements 20 a shown in FIGS. 16 and 17 is stably, smoothly andefficiently manufactured. In this case, the four micro pawl portions 23disposed on each engaging element 20 a are formed from the fourprotruded portions 73 provided on each provisional element 70 a of theprimary molded body 12.

As mentioned above, in the molded surface fastener 2 manufactured inEmbodiment 2, the number of the pawl portions 23 provided on eachengaging element 20 a is four, more than the case of Embodiment 1 asabove. Therefore, in the molded surface fastener 2 of Embodiment 2,higher engaging force than that of the molded surface fastener 1manufactured in the above Embodiment 1 can be easily obtained. A shapeand a size of each pawl portion 23 itself is the same as those ofEmbodiment 1. Therefore, texture on the top surface (upper surface) ofthe molded surface fastener 2 can be improved.

It should be noted that as mentioned above, also in Embodiment 2, it isalso possible that the primary molded body 12 molded in the primarymolding step is provided as it is as the molded surface fastener. Thatis, the molded surface fastener provided in this case is formed suchthat the plurality of provisional elements 70 a as shown in FIGS. 19 and20 stand on the base portion 10 as an engaging element (i.e. theengaging element 70 a in this case has a stem portion 71 and four pawlportions 73). Therefore, the molded surface fastener is provided withhigh peeling strength with respect to a female surface fastener by themicro pawl portions, and excellent texture and a touch feeling can bestably obtained.

Embodiment 3

FIG. 21 is a perspective view illustrating an engaging element of themolded surface fastener manufactured in Embodiment 3. FIG. 22 is a planview illustrating the engaging element only.

The molded surface fastener 3 of Embodiment 3 has a thin plate-shapedbase portion 10 and a plurality of engaging elements 20 b standingvertically on the upper surface of the base portion 10. The eachengaging element 20 b has a stem portion 21 standing on the base portion10, an engaging head portion 22 integrally formed on the stem portion 21and having a disc shape and eight pawl portions 23 protruded on theouter peripheral edge part of the engaging head portion 22. A shape anda size of each pawl portion 23 in Embodiment 3 are substantially thesame as those of each pawl portion 23 formed on the molded surfacefastener 1 of Embodiment 1 as above.

In the engaging element 20 b of Embodiment 3, the eight pawl portions 23are protruded along the diameter direction of the engaging head portion22 from the outer peripheral side surface 22 c of the engaging headportion 22 to an outside. The eight pawl portions 23 are, in a plan viewof the engaging element 20 b shown in FIG. 22, disposed withpredetermined intervals to have an angle of 45° with respect to theadjacent pawl portion 23 based on the center of the engaging headportion 22 showing a circular shape.

In Embodiment 3, the molded surface fastener 3 having the engagingelements 20 b on which eight pawl portions 23 are disposed as above ismanufactured using the manufacturing apparatus 30 having the moldingapparatus 40 and the heat press apparatus 60 as shown in FIG. 7, similarto the case of Embodiment 1 as above.

In the case of Embodiment 3, a cylindrical body 42 b disposed on the diewheel 41 of the molding apparatus 40 has a plurality of penetrationholes 47 penetrating from the outer peripheral surface to the innerperipheral surface along the diameter direction of the cylindrical body42 b and a plurality of concave groove portions (concave portions) 53concaved on the inner peripheral surface of the cylindrical body 42 b asshown in FIG. 23. The penetration holes 47 formed on the cylindricalbody 42 b of Embodiment 3 are formed as same as the penetration holes 47formed on the cylindrical bodies 42 and 42 a of Embodiments 1 and 2, asabove.

A concave groove portion 53 formed on the inner peripheral surface ofthe cylindrical body 42 b of Embodiment 3 is to provide eight pawlportions 23 on each engaging element 20 b of the molded surface fastener3. The concave groove portion 53 has a plurality of first concave grooveportions 53 a formed along C direction, a plurality of second concavegroove portions 53 b formed along M direction (circumferentialdirection), as well as a plurality of third concave groove portions 53 cand a plurality of fourth concave groove portions 53 d formed to have aninclination angle of 45° with respect to the first concave grooveportions 53 a and the second concave groove portions 53 b.

The first concave groove portions 53 a in C direction, the secondconcave groove portions 53 b in M direction as well as the third concavegroove portions 53 c and the plurality of fourth concave groove portions53 d having an inclination angle of 45° with respect to C direction andM direction are formed at predetermined pitches respectively to crossthe circular-shaped outer peripheral edges of the penetration holes 47and continue to the diameter of the penetration holes 47. Therefore, theimaginary extension lines extending the first concave groove portions 53a to the fourth concave groove portions 53 d respectively into thepenetration holes 47 are disposed to cross each other at the centralposition of each penetration hole 47. It is also possible in Embodiment3 that the first concave groove portions 53 a to the fourth concavegroove portions 53 d are formed to extend at a predetermined length onlyfrom the circular-shaped outer peripheral edge of each penetration hole47, as explained referring to FIG. 15 in Embodiment 1 as above.

In Embodiment 3, the primary molding step is conducted using the moldingapparatus 40 having the cylindrical body 42 b on which the penetrationholes 47 and the first concave groove portions 53 a to the fourthconcave groove portions 53 d are provided as shown in FIG. 23, therebythe primary molded body 13 on which a plurality of provisional elements70 b stand on the base portion 10 is molded as shown in FIGS. 24 and 25.In this case, each provisional element 70 b has a primary stem portion71 in a frustum shape standing on the base portion 10 and eightprotruded portions 73 extending from the outer peripheral side surfaceof the upper end part of the primary stem portion 71 to bulge outward.

The eight protruded portions 73 disposed on one provisional element 70 bare molded such that synthetic resin flows into the first concave grooveportions 53 a to the fourth concave groove portions 53 d concaved on theinner peripheral surface of the cylindrical body 42 b from thepenetration holes 47 of the cylindrical body 42 b in the primary moldingstep. Therefore, the eight protruded portions 73 are formed to protrudefrom the outer peripheral side surface of the primary stem portion 71along the diameter direction of the circular-shaped upper surface of theprimary stem portion 71 in C direction, M direction and directionscrossed thereto at an inclination angle at 45°.

The primary molded body 13 of Embodiment 3 having the provisionalelements 70 b shown in FIGS. 24 and 25 are thereafter conveyed to theheat press apparatus 60 in which the secondary molding step isconducted, and each provisional elements 70 b is heated and pressed fromabove by the upper side press roller 61, as same as in the case of theabove-mentioned Embodiment 1.

Thereby, the molded surface fastener 3 having the plurality of engagingelements 20 b shown in FIGS. 21 and 22 are stably, smoothly andefficiently manufactured. In this case, eight micro pawl portions 23disposed on each engaging element 20 b are formed from the eightprotruded portions 73 provided on each provisional element 70 b of theprimary molded body 13.

Since the number of the pawl portions 23 provided on each engagingelement 20 b is eight in the molded surface fastener 3 manufactured inEmbodiment 3 as above, higher engaging force than the cases ofEmbodiment 1 and Embodiment 2 as above can be easily obtained. Further,the size and the shape of each pawl portion 23 is the same as those ofEmbodiment 1 as above, therefore texture of the molded surface fastener3 on the top surface (upper surface) can be improved.

It should be noted that in Embodiment 3, the primary molded body 13molded in the primary molding step can be provided as a molded surfacefastener as it is (i.e., the engaging element 70 b of the molded surfacefastener in this case has a stem portion 71 and eight pawl portions 73).

Further in the present invention, forms such as the number, shape, sizeand disposition of the pawl portion provided on each engaging element ofthe molded surface fastener are not limited to Embodiment 1 toEmbodiment 3 as above and can be arbitrarily changed depending on theuse of the molded surface fastener.

For example, in the die wheel 41 of the molding apparatus 40 conductingthe primary molding step as mentioned above in the present invention,forming pitches of the concave groove portions 51, 52, 53 provided onthe inner peripheral surface of the cylindrical bodies 42, 42 a, 42 bcan be arbitrarily changed not to correspond to the forming pitches ofthe penetration holes 47 provided on the cylindrical bodies 42, 42 a, 42b.

For example, it is possible to set the forming pitches of the concavegroove portions 51, 52, 53 provided on the inner peripheral surface ofthe cylindrical bodies 42, 42 a, 42 b smaller than the forming pitchesof the penetration holes 47 so that the number of the pawl portions 23provided on the engaging head portion 22 is different between eachengaging element.

On the other hand, it is also possible to set the forming pitches of theconcave groove portions 51, 52, 53 larger than the forming pitches ofthe penetration holes 47. Thereby, it can be possible to manufacture themolded surface fastener in which not only the number of the pawlportions provided on the engaging head portion is different between eachengaging element, but also an engaging element on which the pawl portionis provided on the engaging head portion and an engaging element onwhich the pawl portion is not formed on the engaging element stand.

In Embodiment 1 to Embodiment 3 as mentioned above, the plurality ofconcave groove portions 51, 52, 53 are formed to have the same groovewidth and groove depth each other on one cylindrical body 42, 42 a, 42b. In the present invention, however, it is also possible that aplurality of concave groove portions 51, 52, 53 having different groovewidth from each other and different groove depth from each other areprovided on one cylindrical body 42, 42 a, 42 b. Thereby, it is possibleto make a protruded angle and a size of the pawl portion provided on theengaging head portion change between each engaging element. Further, inthe case of providing a plurality of the pawl portions with respect toone engaging head portion, it is possible to provide a plurality of pawlportions having different protruded angles from each other and aplurality of pawl portions having different sizes from each other withrespect to one engaging head portion.

Further, in the present invention, the form of the pawl portion can beeasily changed by changing the forming pattern of the concave grooveportion or the concave portion provided on the cylindrical body of themolding apparatus 40 conducting the primary molding step. Here, theforming patterns of the concave groove portion or the concave portionprovided on the inner side cylindrical body will be explainedillustrating several modification examples using the drawings.

FIGS. 26 to 33 are main part schematic views explaining schematically aposition relation of the penetration holes 47 formed to penetrate fromthe outer peripheral surface to the inner peripheral surface of thecylindrical body 42 b and the concave groove portions 53 or the concaveportions provided on the inner peripheral surface of the cylindricalbody 42 b. In the drawings, two circles show the outer peripheral edgesof the penetration holes 47 drilled on the cylindrical body. The concavegroove portions or the concave portions formed on the inner peripheralsurface of the cylindrical body are shown as a dashed line, and groovebottom surfaces of the concave groove portions or bottom surfaces of theconcave portions are shown in a gray color.

In the modification example 1 shown in FIG. 26, a plurality of concavegroove portions 54 a disposed linearly along C direction are concaved onthe inner peripheral surface of the cylindrical body 42 c as a concaveportion to have a large groove width and to form a stripe pattern.

For example, in Embodiment 1 as mentioned above, only one concave grooveportion 51 which is disposed on the inner peripheral surface of thecylindrical body 42 along C direction is formed with respect to onecircular-shaped penetration hole 47 at a position overlapping with thediameter of the penetration hole 47 as shown in FIG. 9. On the otherhand, in the modification example 1, a plurality of concave grooveportions 54 a are disposed to cross with respect to one circular-shapedpenetration hole 47 by setting the groove width of each concave grooveportion (concave portion) 54 a larger and setting the intervals (formingpitches) between the adjacent concave groove portions 54 a smaller thanthe case of Embodiment 1.

In this case, the number of concave groove portions 54 a formed withrespect to one circular-shaped penetration hole 47 in C direction can beeasily changed by changing appropriately the size of the penetrationholes 47 drilled on the cylindrical body 42 c or the groove widthdimension and the forming interval of the concave groove portions 54 aformed on the inner peripheral surface of the cylindrical body 42 c.

As in the modification example 1, the primary molded body is moldedusing the cylindrical body 42 c on which a plurality of concave grooveportions 54 a in C direction are formed on one circular-shapedpenetration hole 47. Further, the secondary molding step is conducted tothe primary molded body. Thereby, the molded surface fastener having theengaging elements on which three or more pawl portions are regularly orirregularly protruded on the outer peripheral edge part of the engaginghead portion can be stably manufactured.

In Embodiment 1 and the modification example 1, one or a plurality ofconcave groove portions 51, 54 a having a constant groove widthdimension in C direction are provided at constant forming pitches on theinner peripheral surface of the cylindrical body 42, 42 c with respectto one circular-shaped penetration hole 47. In the present invention,however, it is also possible to provide a plurality of concave grooveportions in C direction having different groove width dimensions fromeach other or a plurality of concave groove portions in C directionhaving different forming pitches on the inner peripheral surface of thecylindrical body 42, 42 c.

In Embodiment 1 and the modification example 1, only concave grooveportions in C direction are formed on the inner peripheral surface ofthe cylindrical body. In the present invention, however, only aplurality of concave groove portions 54 b along M direction(circumferential direction) may be provided on the inner peripheralsurface of the cylindrical body 42 d as a concave portion, as in themodification example 2 shown in FIG. 27. It is also possible, as shownin the modification example 3 in FIG. 28, to manufacture the moldedsurface fastener by providing only a plurality of concave grooveportions 54 c inclined at a predetermined angle with respect to Cdirection or M direction on the inner peripheral surface of thecylindrical body 42 e as a concave portion.

In the case of Embodiment 2 as above (FIG. 18) and the case ofEmbodiment 3 as above (FIG. 23), not only the first concave grooveportions 52 a, 53 a along C direction, but also the second concavegroove portions 52 b, 53 b along M direction and the third concavegroove portions 53 c and the fourth concave groove portions 53 d havingan inclination angle at 45° with respect to C direction or M directionare concaved at predetermined pitches on the inner peripheral surface ofthe cylindrical body 42 b, 42 c with respect to the penetration hole 47having a predetermined size.

In the present invention, however, it is also possible in Embodiment 2(FIG. 18), Embodiment 3 (FIG. 23), the modification example 2 (FIG. 27)and the modification example 3 (FIG. 28) that the size of thepenetration hole 47 drilled on the cylindrical body 42 a, 42 b, 42 d, 42e. Further, by making the forming pitches of the concave groove portions52, 53, 54 b, 54 c concaved on the inner peripheral surface of thecylindrical body 42 a, 42 b, 42 d, 42 e small, the number of concavegroove portions communicating to one circular-shaped penetration holecan be changed arbitrarily. In addition, a plurality of concave grooveportions 52, 53, 54 b, 54 c having different groove width dimensionsfrom each other can be provided, or the concave groove portions 52, 53,54 b, 54 c can be provided at irregular forming pitches. Thereby, themolded surface fastener having the engaging elements on which aplurality of pawl portions are protruded regularly or irregularly on theouter peripheral edge part of the engaging head portion can be stablymanufactured.

Next, in the modification example 4 as shown in FIG. 29, a plurality ofconcave groove portions 54 d winding in a wavy shape along C directionare concaved at predetermined forming pitches as a concave portion onthe inner peripheral surface of the cylindrical body 42 f. In thismodification example 4, one or a plurality of concave groove portions 54d communicating to one circular-shaped penetration hole 47 can be formedby changing the size of the penetration hole 47 drilled on thecylindrical body 42 f or the groove width dimension and the formingpitches of the concave groove portions 54 f.

Further, in the modification example 4, the plurality of concave grooveportions 54 d winding in a wavy shape are concaved along C direction.However, in the present invention, it is also possible to concave theplurality of concave groove portions winding in a wavy shape in thecircumferential direction of the cylindrical body 42 f which is Mdirection or along a direction inclined at a predetermined angle withrespect to C direction or M direction.

As in the modification example 4, the molded surface fastener may bemanufactured using the cylindrical body 42 f on which the plurality ofpenetration holes 47 are drilled and the plurality of concave grooveportions 54 d winding in a wavy shape are concaved on the innerperipheral surface. As a result, the molded surface fastener having theengaging elements on which a plurality of pawl portions are protrudedregularly or irregularly on the outer circumferential edge part of theengaging head portion can be stably obtained.

In the modification example 5 as shown in FIG. 30, contrary to the caseof the cylindrical body 42 a in Embodiment 2 as above on which theconcave groove portions 52 are formed along C direction and M direction,a plurality of rectangular-shaped concave portions (recesses) 55 a areformed at predetermined intervals in C direction and M direction so thatthe inner peripheral surface of the cylindrical body 42 g are left alongC direction and M direction.

In the peripheral surface of the cylindrical body 42 g of themodification example 5, the plurality of rectangular-shaped concaveportions 55 a are concaved so that the inner peripheral surface of thecylindrical body 42 g are left in a grid shape along C direction and Mdirection. In the present invention, however, it is also possible toconcave the plurality of rectangular-shaped concave portions so that thegrid shape on the inner peripheral surface of the cylindrical body isformed in a direction inclined at a predetermined angle with respect toC direction and M direction.

In the modification example 6 as shown in FIG. 31, a plurality oftriangle-shaped concave portions (recesses) 55 b are concaved so thatthe inner peripheral surface of the cylindrical body 42 h extendlinearly in various directions (to be left as a radical pattern, forexample). It is also possible in the modification example 6 to changeappropriately the size of the penetration holes 47 drilled on thecylindrical body 42 h and the dimensions and the forming pitches of theconcave portions 55 b.

In the modification example 7 as shown in FIG. 32, a plurality ofsquare-shaped concave portions (recesses) 55 c are concaved on the innerperipheral surface of the cylindrical body 42 i so that the innerperipheral surface of the cylindrical body 42 c and the square concaveportions form a check pattern. It is also possible in the modificationexample 7 to change the size of the penetration holes 47 drilled on thecylindrical body 42 c or the dimensions and forming pitches of theconcave portions 55 c appropriately. Further in the modification example7, the check pattern of concave portions 55 c are formed along Cdirection and M direction, but in the present invention, it is alsopossible to form the check pattern of the concave portions 55 c along adirection inclined at a predetermined angle with respect to C directionor M direction.

In the modification example 8 as shown in FIG. 33, a plurality ofconcave portions (recesses) 55 d in a regular hexagonal shape are formedat predetermined intervals on the inner peripheral surface of thecylindrical body 42 j so that the inner peripheral surface of thecylindrical body 42 j is left as a tortoise shell pattern. In themodification example 7, it is also possible to appropriately change thesize of the penetration holes 47 drilled on the cylindrical body 42 j orthe size and forming pitches of the concave portions 55 d in the regularhexagonal shape.

The molded surface fastener having the engaging elements on which aplurality of pawl portions are regularly or irregularly protruded on theouter peripheral edge part of the engaging head portion can be stablyobtained also by manufacturing the molded surface fastener using eachcylindrical body 42 f to 42 j as shown in the modification example 5 tothe modification example 8.

For the concave groove portion or the concave portion of the presentinvention as above, it is sufficient to have a gap allowing moltensynthetic resin to enter. Further, it is also possible in the presentinvention that a boundary surface between the concave groove portion orthe concave portion and a non-formed portion in which the concave grooveportion or the concave portion is not formed is sloped or curved,thereby formed vaguely. A shape of the concave groove portion or theconcave portion having a vague boundary includes emboss processing orsatin finishing conducted on the inner peripheral surface of thecylindrical body.

And each molded surface fastener using each cylindrical body 42 c to 42j shown in the above-mentioned modification example 1 to modificationexample 8 has high engaging force stably with respect to a femalesurface fastener having loops because a plurality of pawl portions areregularly or irregularly protruded on the engaging head portion of eachengaging element. Further, texture on the top surface (upper surface) ofthe molded surface fastener can be improved.

Embodiment 4

FIG. 34 is a perspective view illustrating an engaging element of amolded surface fastener manufactured in Embodiment 4 of the presentinvention. FIG. 35 is a plan view illustrating the engaging elementonly.

The molded surface fastener 4 of Embodiment 4 has a thin plate-shapedbase portion 10 and a plurality of engaging elements 20 c standingvertically on the upper surface of the base portion 10. Each engagingelement 20 c has a stem portion 21 standing on the base portion 10, adisc-shaped engaging head portion 22 integrally formed on the stemportion 21 and four pawl portions 25 protruded on the outer peripheraledge part of the engaging head portion 22. In this case, the stemportion 21 and the engaging head portion 22 of Embodiment 4 are formedsubstantially same as the stem portion 21 and the engaging head portion22 in the engaging element 20 of Embodiment 1 as above.

In the engaging element 20 c of Embodiment 4, four pawl portions 25 areprotruded from the outer peripheral side surface 22 c of the engaginghead portion 22 in C direction and M direction along the diameterdirection of the engaging head portion 22. These four pawl portions 25are, in a plan view of the engaging element 20 c shown in FIG. 35,regularly arranged at positions of 0°, 90°, 180° and 270° based on thecenter of the engaging head portion 22 showing a circular shape.

Particularly the pawl portion 25 of Embodiment 4 has right and left pairof first pawl portions 25 a protruded from the engaging head portion 22in C direction and a front and rear pair of second pawl portions 25 bprotruded from the engaging head portion 22 in M direction. In thiscase, in the plan view of the engaging element 20 c, two first pawlportions 25 a are protruded at a position relation to be point symmetriceach other based on the center of the engaging head portion 22. Twosecond pawl portions 25 b are protruded at a position relation to bepoint symmetric each other based on the center of the engaging headportion 22. Further, the first pawl portions 25 a and the second pawlportions 25 b of Embodiment 4 has a shape hanging down toward a tip endas a claw of a bird, as the pawl portion 23 of Embodiment 1 as above.

The first pawl portion 25 a of Embodiment 4 is protruded on the outerperipheral side surface 22 c of the engaging head portion 22 at a sizeslightly smaller than the second pawl portion 25 b. Here, the meaning ofthat the first pawl portion 25 a is smaller than the second pawl portion25 b is that at least either dimension (preferably both dimensions) ofthe pawl width dimension and the pawl length dimension (a dimension fromthe outer peripheral side surface 22 c of the engaging head portion 22to the pawl tip end position) of the first pawl portion 25 a is smallerthan the second pawl portion 25 b.

Further, the first pawl portion 25 a and the second pawl portion 25 b ofEmbodiment 4 are formed at a micro size such that each pawl widthdimension is one third or smaller of a dimension of the engaging element20 c at the boundary 24 in M direction (width dimension), preferably onefifth or smaller and more preferably one seventh or smaller. The pawlwidth dimension of the first pawl portion 25 a and the second pawlportion 25 b is specifically set at 0.01 mm or more and 0.10 mm or less,and preferably 0.03 mm or more and 0.08 mm or less. The pawl lengthdimension of the first pawl portion 25 a and the second pawl portion 25b is set at 0.01 mm or more and 0.04 mm or less.

The molded surface fastener 4 of Embodiment 4 having the above structureis manufactured using a manufacturing apparatus 30 a as shown in FIG.36.

The manufacturing apparatus 30 a has a molding apparatus 40 a conductingthe primary molding step and the heat press apparatus 60 heating andpressing the primary molded body 14 molded in the primary molding step.In this case, the heat press apparatus 60 of Embodiment 4 is formed assame as the heat press apparatus 60 of Embodiment 1 shown in FIG. 7 asabove.

The molding apparatus 40 a of Embodiment 4 has a die wheel 41 a driverotating in one direction (anticlockwise direction in the drawings), anextrusion nozzle 45 disposed facing to a circumferential surface of thedie wheel 41 a and extruding molten synthetic resin materialcontinuously, and pickup rollers 46 disposed on a downstream side of theextrusion nozzle 45 in the rotation direction of the die wheel 41 a.

In this case, the extrusion nozzle 45 and the pickup rollers 46 ofEmbodiment 4 are formed as same as the extrusion nozzle 45 and thepickup rollers 46 used for the molding apparatus 40 of theabove-mentioned Embodiment 1 shown in FIG. 7. That is, the pickuprollers 46 have a pair of an upper side holding roller 46 a and a lowerside holding roller 46 b which hold the primary molded body 14 molded atthe die wheel 41 a, as described later, from upper and lower sides.

The die wheel 41 a has an outer side cylindrical body (main sleeve) 42which becomes the mold member, an auxiliary cylindrical body (subsleeve) 43 in a cylindrical shape and disposed closely contacting withan inside of the cylindrical body 42, and a rotation driving roller 44which rotates the cylindrical body 42 and the auxiliary cylindrical body43 in one direction simultaneously. In this case, the die wheel 41 a hasbicylindrical structure in which the outer side cylindrical body 42 andthe inner side auxiliary cylindrical body 43 are concentrically androtatably disposed. Hereinafter, the outer side cylindrical body 42 isreferred to as a first cylindrical body 42, and the inner side auxiliarycylindrical body 43 is referred to as a second cylindrical body 43. Inthe rotation driving roller 44, a cooling jacket distributing a coolantwhich is not shown in the drawings is provided.

The first cylindrical body 42 on the outer side in Embodiment 4 isformed as same as the cylindrical body 42 used for the molding apparatus40 of Embodiment 1 as above. That is, in the first cylindrical body 42of Embodiment 4, a plurality of penetration holes 47 penetrating fromthe outer peripheral surface to the inner peripheral surface of thefirst cylindrical body 42, and a plurality of concave groove portions 51concaved on the inner peripheral surface of the first cylindrical body42 parallel to the central axis direction of the first cylindrical body42 are provided.

The inner side second cylindrical body 43 has, as shown in FIG. 37, aplurality of auxiliary concave groove portions 57 concaved on the outerperipheral surface of the second cylindrical body 43 along thecircumferential direction (M direction) of the second cylindrical body43. The second cylindrical body 43 of Embodiment 4 can be produced usingthe same method as the case of producing the cylindrical body 42 ofEmbodiment 1 as above.

In Embodiment 4, the auxiliary concave groove portions 57 of the secondcylindrical body 43 are formed along the circumferential direction ofthe inner side cylindrical body 42 at predetermined pitches in the axisdirection of the inner side cylindrical body 42 as shown in FIG. 37 soas to have a position relation overlapping with the diameter of thepenetration holes 47 drilled on the first cylindrical body 42 andperpendicular to the concave groove portions 51 of the first cylindricalbody 42.

In this case, the auxiliary concave groove portions 57 of the secondcylindrical body 43 are concaved continuously along the circumferentialdirection so as to cross the penetration holes 47 of the firstcylindrical body 42. The auxiliary concave groove portion 57 has a flatgroove bottom surface and a pair of groove side wall surfaces facing toeach other and disposed parallel to each other so as to have a squarecross section. It should be noted that the auxiliary concave grooveportion 57 may be formed in any shape, and may be formed to have a crosssection in a polygonal shape or substantially U-shape.

The auxiliary concave groove portion 57 of Embodiment 4 has a groovewidth and a groove depth allowing synthetic resin in a molten stateforming the molded surface fastener 4 to flow in. For example, thegroove width (interval between the pair of the groove side wallsurfaces) of the auxiliary concave groove portion 57 is set at from 0.01mm to 0.10 mm and preferably from 0.03 mm to 0.08 mm. Particularly inthis case, the groove width of the auxiliary concave groove portion 57is set at one third or smaller of the dimension of the penetration hole47 in M direction provided on the first cylindrical body 42, preferablyone fifth or smaller, and more preferably one seventh or smaller. Thegroove depth (dimension from the outer peripheral surface of the innerside cylindrical body 42 to the groove bottom surface of the concavegroove portion 51) is set at 0.005 mm or more and 0.05 mm or less,preferably 0.005 mm or more and 0.03 mm or less, and more preferably0.01 mm or more and 0.025 mm or less.

In manufacturing the molded surface fastener 4 using the moldingapparatus 30 a as above shown in FIG. 36, first the primary molding stepfor molding the primary molded body 14 is conducted using the moldingapparatus 40 a. Thereby, the primary molded body 14 on which a pluralityof provisional elements 70 c are integrally molded on the base portion10 as shown in FIGS. 39 and 40 is produced.

The provisional element 70 c of Embodiment 4 has a primary stem portion71 in a frustum shape standing on the base portion 10, two protrudedportions 73 (hereinafter, referred to as first protruded portions 73)which protrude to bulge to an outside from the outer peripheral sidesurface of the upper end part of the primary stem portion 71, a ribportion 74 bulging from the upper surface of the primary stem portion71, and two additional protruded portions 75 (hereinafter, referred toas second protruded portions 75) protruded continuously from the bothend edges of the rib portion 74 so as to bulge to an outside of theprimary stem portion 71.

The two first protruded portions 73 disposed on the provisional element70 c are molded in the primary molding step by allowing synthetic resinto flow in from the penetration hole 47 of the first cylindrical body 42to the concave groove portion 51 concaved on the inner peripheralsurface of the first cylindrical body 42. Therefore, the two firstprotruded portions 73 are protruded to bulge to an outside from theouter peripheral side surface of the primary stem portion 71 along Cdirection.

The rib portion 74 and two second protruded portions 75 disposed on theprovisional element 70 c are molded by allowing synthetic resin to flowin from the penetration hole 47 of the first cylindrical body 42 to theauxiliary concave groove portion 57 concaved on the outer peripheralsurface of the second cylindrical body 43. Therefore, the rib portion 74and two protruded portions 75 are continuously formed at a heightposition upper than the upper surface of the primary stem portion 71along M direction.

The primary molded body 14 molded at the die wheel 41 a of the moldingapparatus 40 a is peeled off continuously from the outer peripheralsurface of the die wheel 41 a by the pickup rollers 46 of the moldingapparatus 40 a. At this time, the two first protruded portions 73 andthe two second protruded portions 75 disposed on the provisional element70 c are pressed by the upper side holding roller 46 a from above andpartially bent and deformed. As a result, as in the case of Embodiment 1as above, the first protruded portions 73 and the second protrudedportions 75 can be protruded parallel or substantially parallel to theupper surface of the base portion 10, or sloped or curved downward tothe base portion 10.

Thereafter, the primary molded body 14 is conveyed to the heat pressapparatus 60 to conduct the secondary molding step. In the secondarymolding step, as in the case of Embodiment 1 as above, the primarymolded body 14 passes between the upper side press roller 61 and thelower side press roller 62, thereby an upper end part of eachprovisional element 70 c of the primary molded body 14 is heated andpressed from above by the upper side press roller 61, and the upper endpart of the provisional element 70 c is compressed.

Thereby, the molded surface fastener 4 having the plurality of engagingelements 20 c as shown in FIG. 34 and FIG. 35 is stably, smoothly andefficiently manufactured. In this case, two first pawl portions 25 aprotruded from the engaging head portion 22 of each engaging element 20c in C direction and two second pawl portions 25 b protruded from theengaging head portion 22 in M direction are respectively formed from thetwo first protruded portions 73 and the two second protruded portions 75(additional protruded portions 75) provided on each provisional element70 c of the primary molded body 14. Therefore, four pawl portions 25 intotal are formed on the engaging head portion 22 of each engagingelement 20 c.

In Embodiment 4, in order to provide four pawl portions 25 with respectto the engaging head portion 22 of one engaging element 20 crespectively, the die wheel 41 a of the molding apparatus 40 a has theouter side first cylindrical body 42 for molding the first protrudedportions 73 and the inner side second cylindrical body 43 (auxiliarycylindrical body 43) for molding the second protruded portions 75(additional protruded portions 75). Therefore, a forming pattern of theconcave groove portions 51 concaved on the inner peripheral surface ofthe first cylindrical body 42 and a forming pattern of the auxiliaryconcave groove portions 57 concaved on the outer peripheral surface ofthe second cylindrical body 43 can be formed in a simple shape (pattern)respectively.

In the case of Embodiment 2 as above in which four pawl portions 23 areprovided on the engaging head portion 22 of one engaging element 20 a,for example, two kinds of concave groove portions 52 which are the firstconcave groove portion 52 a in C direction and the second concave grooveportion 52 b in M direction needs to be provided at predeterminedpatterns on the inner peripheral surface of one cylindrical body 42 a,as shown in FIG. 18. On the other hand, in Embodiment 4, the concavegroove portion 51 is concaved only in C direction on the innerperipheral surface of the first cylindrical body 42 on an outer side,and the auxiliary concave groove portion 57 is concaved only in Mdirection on the outer peripheral surface of the second cylindrical body43 on an inner side, as shown in FIG. 38.

In Embodiment 4 as above, the concave groove portions required toprovide the pawl portion 25 on the engaging head portion 22 can beprovided separately on the outer side first cylindrical body 42 and onthe inner side second cylindrical body 43. Therefore, in the case ofEmbodiment 4, the first cylindrical body 42 and the second cylindricalbody 43 can be relatively easily produced compared with a case offorming a plurality of concave groove portions 52 in differentdirections with respect to one cylindrical body 42 a as in Embodiment 2as above.

And in the molded surface fastener 4 of Embodiment 4 thus manufactured,four pawl portions 25 are provided on each engaging element 20 c,thereby high engaging force can be easily obtained. Further, the fourpawl portions 25 provided to enhance the engaging strength are formed ina smaller size with respect to the engaging head portion 22. Thereby,the pawl portions 25 can less affect to touch feeling of the moldedsurface fastener 4. Therefore, texture on the top surface (uppersurface) of the molded surface fastener 4 can be improved.

In Embodiment 4, as mentioned above, it is also possible that theprimary molded body 14 molded in the primary molding step and having aplurality of provisional elements 70 c as shown in FIG. 39 and FIG. 40is provided as it is as the molded surface fastener. In this case, theprovisional elements 70 c, the primary stem portion 71, the protrudedportion (first protruded portion) 73, the rib portion 74 and theadditional protruded portion (second protruded portion) 75 of theprimary molded body 14 as shown in FIG. 39 and FIG. 40 are used as theengaging element, the stem portion, the pawl portion, the rib portionand the additional protruded portion of the molded surface fastener(that is, the engaging element 70 c of the molded surface fastener hasthe stem portion 71, the pawl portion 73, the rib portion 74 and theadditional pawl 75). In this case, the engaging head portion is notprovided on the engaging element.

Further in this case, it is preferable to horizontally convey the moldedsurface fastener molded with the molding apparatus 40 a while beingheated or blowing hot air from above to the conveyed molded surfacefastener, for example. Thereby, the pawl portion and the additional pawlportion of each engaging element can be stably protruded from the outerperipheral side surface of the upper end part of the stem portion or therib portion in a frustum shape in a horizontal direction parallel to theupper surface of the base portion 10, or to hang downward toward thebase portion 10 rather than the horizontal direction.

In Embodiment 4 as above, the two first pawl portions 25 a in Cdirection and the two second pawl portions 25 b in M direction providedon the engaging element 20 c have different sizes from each other asmentioned above, and the first pawl portions 25 a are formed to beslightly smaller than the second pawl portions 25 b. However, inEmbodiment 4, the relation between the sizes of the first pawl portions25 a and the second pawl portions 25 b is not limited in particular.

For example, the size of the concave groove portion 51 concaved on theinner peripheral surface of the first cylindrical body 42 and the sizeof the auxiliary concave groove portion 57 concaved on the outerperipheral surface of the second cylindrical body 43 may be changed. Asa result, it is possible to form the first pawl portions 25 a in Cdirection provided on the engaging element 20 c larger than the secondpawl portions 25 b in M direction, or to form the first pawl portion 25a in C direction and the second pawl portions 25 b in M direction at thesame size.

In the present invention, the forming pattern of the concave grooveportions or concave portions concaved on the inner peripheral surface ofthe outer side first cylindrical body 42 and the forming pattern of theauxiliary concave groove portions or the auxiliary concave portionsconcaved on the outer peripheral surface of the inner side secondcylindrical body 43 in the molding apparatus 40 a can be changedappropriately depending on the number, disposition and a size of thepawl portions provided on the engaging element.

In Embodiment 4 as above, for example, the concave groove portions 51along C direction are concaved on the inner peripheral surface of thefirst cylindrical body 42, and the auxiliary concave groove portions 57along M direction are concaved on the outer peripheral surface of thesecond cylindrical body 43. In the invention, however, it is alsopossible that the concave groove portions along M direction are concavedon the inner peripheral surface of the first cylindrical body 42 and theauxiliary concave groove portions along C direction are concaved on theouter peripheral surface of the second cylindrical body 43.

Further, in a case that eight pawl portions are provided to one engagingelement, for example, as an example of forming patterns of the concavegroove portions 52 of the first cylindrical body 42 a and the auxiliaryconcave groove portions 58 of the second cylindrical body 43 a is shownin FIG. 41, the first concave groove portions 52 a along C direction andthe second concave groove portions 52 b along M direction are concavedon the inner peripheral surface of the outer side first cylindrical body42 a. In the inner peripheral surface of the inner side secondcylindrical body 43 a, auxiliary concave groove portions 58 disposed tohave an inclination angle at 45° with respect to C direction and Mdirection are concaved. The molding apparatus 40 a having the firstcylindrical body 42 and the second cylindrical body 43 as above is used,thereby the molded surface fastener having the engaging elements onwhich eight pawl portions are protruded on the outer peripheral edgepart of the engaging head portion at regular intervals can be stablymanufactured.

Further, as the forming pattern of the concave groove portions orconcave portions concaved on the inner peripheral surface of the firstcylindrical body and the forming pattern of the auxiliary concave grooveportions or auxiliary concave portions concaved on the outer peripheralsurface of the inner side second cylindrical body, it is also possibleto use the patterns explained in the modification example 1 to themodification example 8 as mentioned above (see FIG. 26 to FIG. 33).

Further, in the above-mentioned Embodiment 1 to Embodiment 3 and themodification example 1 to the modification example 8, explained is acase conducting the primary molding step of the molded surface fastenerusing the molding apparatus 40 having the die wheel 41 shown in FIG. 7.In Embodiment 4, explained is a case conducting the primary molding stepof the molded surface fastener using the molding apparatus 40 a havingthe die wheel 41 a shown in FIG. 36. However, in the present invention,a molding apparatus having the other forms can be used in the primarymolding step in manufacturing the molded surface fastener.

As an example of the molding apparatus having another form to mold theprimary molded body, an apparatus having a die wheel drive rotating inone direction, a press wheel disposed apart from the die wheel at apredetermined interval and drive rotating in the opposite direction tothe direction of the die wheel and an extrusion nozzle extruding moltensynthetic resin material toward between the die wheel and the presswheel can be used, as same as the Patent Document 3 as above (see FIGS.42 and 43).

In this case, the die wheel of the molding apparatus in another form hasthe same structure as the die wheel 41 explained in Embodiment 1 asabove or the die wheel 41 a explained in Embodiment 4.

That is, the die wheel in this form has a cylindrical body 42 on which aplurality of penetration holes and a plurality of concave grooveportions are formed, and a rotation driving roller 44 rotating thecylindrical body 42, as explained in Embodiment 1 as above. Otherwise,it has a first cylindrical body 42 on which a plurality of penetrationholes and a plurality of concave groove portions are formed, a secondcylindrical body (auxiliary cylindrical body) 43 on which auxiliaryconcave groove portions are concaved on the outer peripheral surface anda rotation driving roller 44 rotating the first cylindrical body 42 andthe second cylindrical body 43, as explained in Embodiment 4 as above.

Further in the present invention, as one more example of moldingapparatus in another form, it is possible to use an apparatus having amolding side belt mechanism rotating to travel in one direction, a pressside belt mechanism disposed apart from the molding side belt mechanismat a predetermined interval and rotating to travel in the oppositedirection to the direction of the molding side belt mechanism and anextrusion nozzle disposed facing to the outer peripheral surface of thebelt of the molding side belt mechanism and continuously extrudingmolten resin material.

The molding side belt mechanism has an endless belt to become a moldmember and a pair of rotation roller which the endless belt is woundaround and rotating to travel the endless belt in one direction. In thiscase, in the endless belt, a plurality of penetration holes and aplurality of concave groove portions similar to the penetration holesand the concave groove portions provided on the cylindrical body ofEmbodiment 1 as above are provided to mold the stem portions of theprimary molded body. Further, the press side belt mechanism has anendless belt for press and a pair of rotation rollers which the endlessbelt for press is wound around and rotating to travel the endless beltfor press.

Otherwise, as a form of the molding side belt mechanism, the one havingan outer side first endless belt to become a mold member, a secondendless belt (auxiliary endless belt) disposed closely contacting withthe inside of the outer side first endless belt, and a pair of rotationrollers which the first endless belt and the second endless belt arewound around and rotating to travel the belts in one directionsimultaneously.

In this case, in the first endless belt, a plurality of penetrationholes and a plurality of concave groove portions similar to thepenetration holes and the concave groove portions provided on the firstcylindrical body of Embodiment 4 as mentioned above are provided. In thesecond endless belt, a plurality of auxiliary concave groove portionssimilar to the auxiliary concave groove portions provided on the outerperipheral surface of the second cylindrical body of Embodiment 4 asmentioned above are provided.

Also by conducting the primary molding step to mold the primary moldedbody by using molding apparatuses in yet another form having the diewheel and the press wheel as above or using molding apparatuses in yetanother form having the molding side belt mechanism and the press sidebelt mechanism, the molded surface fastener 1 to the molded surfacefastener 4 as explained in Embodiment 1 to Embodiment 4 can be stablymanufactured.

REFERENCE SIGNS

1, 2, 3, 4: molded surface fastener

10: base portion

11, 12, 13: primary molded body

14: primary molded body

20: engaging element

20 a, 20 b: engaging element

20 c: engaging element

21: stem portion

22: engaging head portion

22 a: head portion top end surface

22 b: head portion back surface

22 c: outer peripheral side surface

23: pawl portion

24: boundary

25: pawl portion

25 a: first pawl portion

25 b: second pawl portion

30, 30 a: manufacturing apparatus

40, 40 a: molding apparatus

41, 41 a: die wheel

42: cylindrical body (sleeve or first cylindrical body)

42 a to 42 j: cylindrical body

43, 43 a: auxiliary cylindrical body (second cylindrical body)

44: rotation driving roller

45: extrusion nozzle

46: pickup roller

46 a: upper side holding roller

46 b: lower side holding roller

47: penetration hole

51, 51 a: concave portion (concave groove portion)

52: concave portion (concave groove portion)

52 a: first concave groove portion

52 b: second concave groove portion

53: concave portion (concave groove portion)

53 a: first concave groove portion

53 b: second concave groove portion

53 c: third concave groove portion

53 d: fourth concave groove portion

54 a, 54 b: concave portion (concave groove portion)

54 c, 54 d: concave portion (concave groove portion)

55 a, 55 b: concave portion (concave groove portion)

55 c, 55 d: concave portion (concave groove portion)

57: auxiliary concave groove portion

58: auxiliary concave groove portion

60: heat press apparatus

61: upper side press roller (calender roller)

62: lower side press roller (calender roller)

70, 70 a: provisional element

70 b, 70 c: provisional element

71: primary stem portion

73: protruded portion (first protruded portion)

74: rib portion

75: additional protruded portion (second protruded portion)

A: height dimension of engaging element

B: diameter of engaging head portion

C: height dimension of engaging head portion

D: diameter of engaging element at boundary

E: bulging dimension of engaging head portion

F: pawl width dimension

θ: bulging angle of engaging head portion

MD: machine direction

CD: crossing direction

1. A molding apparatus used for manufacturing a molded surface fastenermade of synthetic resin in which a plurality of engaging elements standon an upper surface of a base portion, the molding apparatus including amolding member, a driving part rotating the mold member at apredetermined speed and an extrusion nozzle extruding molten syntheticresin material toward the mold member, wherein: the mold member isprovided with a plurality of penetration holes drilled to penetrate froman outer peripheral surface to an inner peripheral surface and aplurality of concave portions concaved on the inner peripheral surface,and each penetration hole of the mold member communicates to at leastone of the concave portions.
 2. The molding apparatus according to claim1, wherein: the mold member has a cylindrical shape, and a die wheel isformed using the mold member and the driving part.
 3. The moldingapparatus according to claim 1 including an auxiliary mold memberdisposed closely contacting with the inner peripheral surface of themold member on an inside of the mold member and in which auxiliaryconcave portions communicating to the penetration holes of the moldmember are concaved on an outer peripheral surface, wherein theauxiliary mold member is rotated synchronously with the mold member. 4.The molding apparatus according to claim 1, wherein: the concave portionis a linear concave groove portion or a concave groove portion curved ina wavy shape.
 5. The molding apparatus according to claim 4, wherein: agroove width of each concave groove portion is set at 0.005 mm or moreand 0.1 mm or less, and a groove depth of each concave groove portion isset at 0.005 mm or more and 0.05 mm or less.